Session 2.3: Pressure Storage Systems I. Dr. S. Rau, J.S. Colom. 25 th 29 th September 2006 Ingolstadt. Session 1.2: Introductory Lectures. K.

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1 Session 2.3: Pressure Storage Systems I Dr. S. Rau, J.S. Colom 25 th 29 th September 2006 Ingolstadt Session 1.2: Introductory Lectures K. Hall

2 CV Dr. Steffen Rau Address: Dynetek Europe GmbH Breitscheider Weg 117a Ratingen, GERMANY 2.3 Pressure Storage Systems : Study of Mechanical Engineering with specialisation in plastics processing at Aachen University of Technology (RWTH Aachen) followed by work as scientific assistant at the Institute of Plastics Processing (Institut für Kunststoffverarbeitung (IKV)) of Aachen University of Technology : Plant engineer at Mannesmann Cylinder Systems GmbH in Dinslaken; development and production of composite pressure vessels for breathing air systems, industrial gas applications and CNG powered vehicles today: Technical Director and Authorized Representative of Dynetek Europe GmbH in Ratingen; development and production of composite pressure vessels for industrial gas applications as well as for CNG and hydrogen powered vehicles Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 2

3 CV J.S. Colom 2.3 Pressure Storage Systems Address: AIR LIQUIDE CRCD 1, chemin de la Porte des Loges Jouy-en-Josas, FRANCE Tel : +33 (0) Fax : +33 (0) jayasitra.colom@airliquide.com 2002 : Master s degree in General Engineering (Ecole des Mines de Nancy, France) Energy and Gas Applications : AIR LIQUIDE Research Engineer (CRCD, France) High pressure tank filling technologies Metal hydride storage systems 2006 : AIR LIQUIDE Project Coordinator (CRCD, France) H2 storage & distribution issues Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 3

4 Lectures on Compressed H2 Storage Technology, Dr. S. Rau, J.S. Colom Abstract: 2.3 Pressure Storage Systems The first part will focus on cylinders for storage of compressed gaseous hydrogen. This includes different designs, manufacturing technologies, performance, and testing to ensure safety respectively to achieve a certification based on actual standards. The second part will focus on the high pressure cylinder integration issues in a car. Associated devices and components, examples of architecture and storage concepts will be described. The refueling process for high pressure cylinders on-board vehicles is also a critical aspect of the application. Stakes and challenges of refueling will be adressed. Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 4

5 Lectures on Compressed H2 Storage Technology Table of Content Introduction to hydrogen storage systems Cylinder designs Cylinder manufacturing technologies Cylinder performance, testing and safety Integration of high pressure storage systems in cars Refueling issues Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 5

6 Hydrogen storage system design Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 6

7 Table of Content Introduction to hydrogen storage systems Cylinder designs Cylinder manufacturing technologies Cylinder performance, testing and safety Integration of high pressure storage systems in cars Refueling issues Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 7

8 Cylinder desings Type 1 Type 2 all metal 1.0 to 1.5 kg/l* Hoop wrapped seamless liner 0.65 to 1.3 kg/l* Type 3 Type 4 Fully wrapped metallic liner 0.3 to 0.45 kg/l* Fully wrapped non-load carrying (plastic) liner 0.3 to 0.45 kg/l* Typical weight range for 200 bar cylinders Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 8

9 700 bar Requirements Today, in fuel cell cars a stored hydrogen mass of 4 kg is considered to be sufficient for a driving range of 640 km (400 miles). This range fulfills the requirements of several OEM s to support the commercialisation of fuel cell vehicles. 300 Required Internal Volume [l] Service Pressure [bar] Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 9

10 Table of Content Introduction to hydrogen storage systems Cylinder designs Cylinder manufacturing technologies Cylinder performance, testing and safety Integration of high pressure storage systems in cars Refueling issues Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 10

11 Lectures on Compressed H2 Storage Technology Liner Production Cycle From Steel Plate Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 11

12 Polymer Liner Production by Rotational Moulding Charging the Mould Heating and Fusion Heat Heat Heat Heat Heat Heat Heat Heat Holding station Oven Load station Holding station Unload station Temperature ( C) Powder heating Melting Heating stage Heating chamber Sintering Mould suface Hours Cooling Cooling stage Mould inside 1.0 Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 12

13 Composite Manufacturing Fiber Raw Material Impregnation Bath/ Epoxy Resin Filament Winding Curing Oven Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 13

14 Filament Winding Video 1 Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 14

15 Filament Winding Video 2 Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 15

16 Volumetric Expansion Test Overflow pipe D h Measuring jar Pressure sensor Precision scale (1 mg accuracy) M Pressurisation unit Water inlet Test cylinder Outer vessel Control and recording system Test Pressure Change in Volume Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 16

17 Table of Content Introduction to hydrogen storage systems Cylinder designs Cylinder manufacturing technologies Cylinder performance, testing and safety Integration of high pressure storage systems in cars Refueling issues Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 17

18 1st Design Step: FEA and verification Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 18

19 Safety: Testing of CH2 Cylinders tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Test Requirements: Pressurised with liquid till burst with rate < 1.4 MPa/s burst pressure > 2.35 x working pressure and > minimum design burst pressure Only Type 4 Cylinders Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 19

20 Safety: Burst Test Berstversuch "700 bar H2-Behälter" 2000 Behälterbezeichnung: VC 23 Serial no. VC23 15-Aug Innendruck in Pressure [bar] ,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 Volumenänderung in Liter max. Innendruck: 1913,0 bar Volumenänderung bei max. Innendruck: 3,76 l Volume change [litre] Innendruck als Funktion der Volumenänderung beim Wasserberstversuch am Behälter VC23 Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 20

21 Safety: Testing of CH2 Cylinders tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Test Requirements: Pressurised with liquid from 2 MPa to 1.25 x working pressure 3 x number of filling cycles or max. 15,000 NO leak Only Type 4 Cylinders Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 21

22 Safety: Cycle Test 2 MPa to 87.5 MPa Serial no. VC06 leak after cycles in side wall Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 22

23 Safety: Testing of CH2 Cylinders tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Test Requirements: preconditioned by impact exposure to five chemicals 5000 cycles to 1.25 x working pressure x working pressure burst pressure > 1.8 x working pressure Only Type 4 Cylinders Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 23

24 Safety: Chemical Exposure Test Impact by Pendulum Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 24

25 Safety: Chemical Exposure Test Impact by Pendulum Exposure to five chemicals: 1.Sulphuric acid - 19% solution by volume in water 2.Sodium hydroxide - 25% solution by weight in water 3.Methanol/gasoline - 5/95 % concentration 4.Ammonium nitrate - 28% solution by weight in water 5.Windshield washer fluid (50% by volume solution of methyl alcohol and water) Testing: 5000 cycles to 1.25 x working pressure x working pressure Burst pressure > 1.8 x working pressure Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 25

26 Safety: Testing of CH2 Cylinders Safety: Testing of CH2 Cylinders tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Test Requirements: Pressurised with H2 to working pressure Fire source length: 1.65 m NO burst but venting through the temperature triggered pressure relief device (TPRD) Only Type 4 Cylinders Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 26

27 Safety: Bonfire Test Video Play Video Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 27

28 Safety: Testing of CH2 Cylinders tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Test Requirements: Pressurised with gas to working pressure Armour Piercing Bullet 7.62 mm Impact at an angle of 45 NO burst but venting through the entrance (and exit) opening Only Type 4 Cylinders Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 28

29 Safety: Bullet Test Video Play Video Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 29

30 Safety: Bullet Test Results (200 bar CNG cylinder) Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 30

31 Safety: Testing of CH2 Cylinders tests of raw material corrosion test hydraulic pressure test burst test cycle test (ambient temperature) cycle test (extreme temperature) leak before break test chemical exposure test bonfire test penetration (bullet) test composite flaw tolerance test accelerated stress rupture test impact damage (drop) test leak test permeation test boss torque test hydrogen cycle test Only Type 4 Cylinders 200 bar with Al-Liner 350 bar with Al-Liner 700 bar with SS-Liner Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 31

32 Lectures on Compressed H2 Storage Technology, Result of design and testing: Type approval for the on-board storage of compressed hydrogen in vehicels Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 32

33 Table of Content Introduction to hydrogen storage systems Cylinder designs Cylinder manufacturing technologies Cylinder performance, testing and safety Integration of high pressure storage systems in cars Refueling issues Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 33

34 Lectures on Compressed H2 Storage Technology Integration challenges 700 bar components availability : design adapted to vehicle requirements, optimisation (in-tank integration) and cost decrease Crash protection : localization of the tank in the car Safety issues High pressure management in case of fire H2 external leak management system : detection / appropriate procedures definition Monitoring : safety, maintenance, control For more information, session 1.4 Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 34

35 Integration architecture : examples Temperature sensor PRD Temperature sensor PRD 700bar tank Filling connector 700bar tank Filling connector Pressure Transmitter Toward FC or ICE 700bar solenoid valve 700bar regulator Pressure Transmitter Toward FC or ICE 700bar regulator Low pressure solenoid valve Pressure Relief Valve Toward atmosphere Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 35

36 Two storage concepts ON-BOARD STORAGE EXCHANGEABLE RACK +LJK SUHVVXUH WDQNLV LQWHJUDWHG LQ WKH FDU PSA +LJK SUHVVXUH WDQNFDQ EH UHPRYHG IURP WKH FDU 'LUHFWIXHOLQJ LQDIXHOLQJ VWDWLRQ Air Liquide Air Liquide 5HPRWH IXHOLQJ LQD ILOOLQJ FHQWHU Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 36

37 Two storage concepts On-Board storage Exchangeable rack Interest No change in fueling habits Possibility to use the existing infrastructure Main applications Challenges Large vehicles (cars, buses) Long term solution Develop infrastructure Fast filling (< 3min) Small vehicles (scooter), captive fleet Short term solution Resistant and light structure Regulations adapted to the application Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 37

38 On-board storage : integration examples Fuel cell module Power distribution unit (PDU) HV- Battery Cooling system Electric motor System module Hydrogen pressure tanks Daimler Chrysler Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 38

39 Exchangeable rack : integration examples PSA Due to crash issues, the swap-rack is mainly at the centre of the vehicle and at least kept away from the rear bumper. PSA Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 39

40 Table of Content Introduction to hydrogen storage systems Cylinder designs Cylinder manufacturing technologies Cylinder performance, testing and safety Integration of high pressure storage systems in cars Refueling issues Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 40

41 Refueling challenges Objective : To supply high flow of high pressure hydrogen with high reliability Station Interface Car (HP vessel) Technological ability Safety management Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 41

42 Station design : technologies H 2 source LP storage Compression HP storage Dispensing LH EDU EDU GH +3 *+ Design depends on H2 source and station capacity Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 42

43 Station design : safety Main risks are relative to H 2 and high pressure Leakages, Fire, Explosions Reduce occurence Passive device H 2 / Fire detection device Pressure release device Active device Leak detection Electrostatic discharge Reduce gravity Protective wall Safety distance Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 43

44 Interface station / vehicle Fuell Cell Vehicle Break-away H2- Dispenser Fuelling nozzle Receptacle Nozzle Holster Fuelling hose WEH Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 44

45 Fueling components : breakaway system WEH Break-away coupling for H 2 filling stations for cars Function : separating the coupling in the event of an accidental deployment Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 45

46 Fueling components : linear valve Fueling components : linear valve Pneumatically actuated linear valve for use at hydrogen filling stations WEH Function : to control the H 2 flow rate during filling Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 46

47 Fueling components : nozzle and receptacle WEH Pistol grip nozzle and corresponding receptacle WEH WEH Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 47

48 Filling : physical basis Theory : Isentropic compression T B T A B = T A P P A B P γ 1 γ High pressure vessel heat T B = H 2 In practice heat transfer through tank wall and outside environment ( H + H H ) comp Fast filling results in a temperature increase in the tank f in heat Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 48

49 Filling : target density P (bar) 700 Pressure «overshoot» Target density Target density line Temperature increase during filling P, T Vessel specifications Ps = 700bar at 15 C Target density Perfect gas law Target density line +15 T ( C) Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 49

50 Filling : vessel operating window P (bar) Over cooling Over pressure Over filling Target density OPERATING WINDOW Target density line Over heating P, T Vessel specifications Ps = 700bar at 15 C -40 C / +85 C Max P = 875bar T ( C) Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 50

51 Filling challenges Objectives Target density Fast filling : < 3min Constraints Maximum operating pressure Temperature limits Challenges Control Temperature Density Optimum between high filling rate (target density) and fast filling (filling time) Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 51

52 Lectures on Compressed H2 Storage Technology Thank you for your attention Session 2.3 Pressure Storage Systems Dr. S. Rau, J.S. Colom 52

53 Session 2.3: Pressure Storage Systems I Dr. S. Rau, J.S. Colom 25 th 29 th September 2006 Ingolstadt Session 1.2: Introductory Lectures K. Hall