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Heinrich Lienkamp , Ashok Rastogi Infraserv Höchst - Frankfurt Germany

Experience with FC-Vehicles & Hydrogen Infrastructure in ZERO REGIO. Heinrich Lienkamp , Ashok Rastogi Infraserv Höchst - Frankfurt Germany. www.zeroregio.com. Outline Brief presentation of Aims, activities & highlights in Zero Regio Frankfurt, Germany Mantova, Italy

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Heinrich Lienkamp , Ashok Rastogi Infraserv Höchst - Frankfurt Germany

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  1. Experience with FC-Vehicles & Hydrogen Infrastructure in ZERO REGIO Heinrich Lienkamp, Ashok Rastogi Infraserv Höchst - Frankfurt Germany www.zeroregio.com Rastogi / Lienkamp

  2. Outline Brief presentation of Aims, activities & highlights in Zero Regio Frankfurt, Germany Mantova, Italy Operational experience Some events Lessons learnt Collection and Assessment of Data Comparison with the state of the art Concluding Remarks; Next steps Rastogi / Lienkamp

  3. Industrial Park Höchst 4.6 km2 area 72 km Streets 80 Companies Over 22000 Workforce & 30 mil.Nm3/yr By-product H2 Rastogi / Lienkamp

  4. Service Station Frankfurt Area = 4.062 m2 350 & 700 bar GH2 LH2 Dipensers. Photovoltaic 8 kW Opened on 17.11.2006 Rastogi / Lienkamp

  5. H2 - Infrastructure in Germany Hydrogen center in Industry park, Höchst Existing infrastructure By-product H2 is collected, conditioned, compressed (250 bar) Trailer station Ionic fluid compressor (900 bar) in Hydrogen center Agip station 1.7 km from H2-center Hydrogen transport to station via HP-pipeline (1000 bar) CGH2 dispensers, 350 bar and 700 bar one each LH2 dispenser (Truck supply of LH2) Agip station opened on Nov. 17, 2006 Rastogi / Lienkamp

  6. Lay out HP Pipeline in Höchst Rastogi / Lienkamp

  7. Some Design Details Overground: Hanging pipe system Underground: Tubing with PE sleeve in sandbed 1.4462 Material Din = 18 mm Dout = 33.7 mm Pmax =1000 bar Welded construction Leakproof by definition HP-H2-Transport system is one of its kind worldwide Rastogi / Lienkamp

  8. Compression Scheme F F 225 bar H2 storage H2 Disp 350 bar 25 m³ PIC G 265 HP Pipeline- System 900 bar Compressor H2 Disp.700bar Hg -filter (Option) Particle- filter 300 bar Hydrogen- Refuelling Station Buffer 2.4 m3 Cold-Fill(-40°C) Rastogi / Lienkamp

  9. Ionic Fluid Compressor – working principle PLC Rastogi / Lienkamp

  10. Ionic Fluid Compressor • Special Features: • Ionic liquid no vapor pr. • Compressor capacity = • 900 Nm3/hr or • 1.335 kg/min • First time in Zero Regio for H2 - 900 bar Rastogi / Lienkamp

  11. Hydrogen-Dispensers – Höchst GH2 700 bar GH2 350 bar LH2 Rastogi / Lienkamp

  12. Service Station Frankfurt Rastogi / Lienkamp

  13. Experience with infrastructure in Germany High availability inspite of some problems: Filters in the cooling system of the compressor Some valves failed on the compressor system Some loose fittings leading to system failure Ionic Compressor overhauled in 2nd year of operation Outage for 3 months Filter problems in the third year, regular maintenance reqd. Insufficient purging of the pipeline initially Control valves at dispenser & minor electronic problems Incident reporting and management approach important One accident in the first year, no H2 discharge Rastogi / Lienkamp

  14. Operational Experience in Germany Rastogi / Lienkamp

  15. Damage of 700 bar Dispenser by accident Cause: Passenger car runs into dispenser Effect: major damage of dispenser and the installed techniqueNo accidental escape of hydrogen Action: Repair / replacement of dispenser Operational Experience in Germany Rastogi / Lienkamp

  16. Servicestation Mantova Rastogi / Lienkamp

  17. H2 - Infrastructure in Mantova, Italy On-site production facility (CPO – reformer) Small unit with 20 Nm3/hr Construction completed and in operation from July 2008 Truck transport from an industrial reformer (back-up) 350 bar GH2 dispenser (Cars homologated for 200 bar) Delay partly due to approval formalities A mobile refueller initially (AP 100) Integration in multi-energy Agip service station 17.000 m2, Car Wash, Cafè Shop Opening ceremony took place on 21 Sept. 2007 Rastogi / Lienkamp

  18. CPO Reformer by Eni Rastogi / Lienkamp

  19. Suitable for intermittent operation 3 Compaigns in 2009 20 kg. H2 in April 09 40 kg. H2 in July 09 (40 kg. Storage capacity) 40 kg. H2 in Oct. 09 One day for plant start-up and shut down High quality achieved (CO< 0.1 ppm) Plant optimised for automatic operation 20 Nm3/hr. too high for 3 cars Other applications planned at the service station On-site Hydrogen Production in Mantova Rastogi / Lienkamp

  20. Dedicated Fleets Range: 250 km (@350 bar)Maximum speed: 135 km/hAcceleration: 0-50 km/h within 7 sNuvera PEM 70 kW 3 cars Range: 160 km (@350 bar)Maximum speed: 140 km/hBallard PEM 72 kW 5 cars, one with 700 bar storage Rastogi / Lienkamp

  21. Beauty and the Beast F-Cell serving A-380 !! Rastogi / Lienkamp

  22. Operational Performance of the vehicles in 2008 46 Some Demonstration Data Mileage Operating hours F-Cell No. 29 F-Cell No. 59, 60, 61 F-Cell No. 49 (700 bar) The operational performance 2008 was lower than expected Rastogi / Lienkamp

  23. In general all FCV‘s functioned better than expected Regular maintenance was performed Tank leak tests TÜV examinations Minor repairs could be done on site No road calls One accident due to drivers negligence One car was taken out of service in Sept. 2009 due to IPT defect (Integrated PowerTrain failure) SOME INCIDENTS with Fleet Rastogi / Lienkamp

  24. Frankfurt station is used also by other customers For 350 bar dispenser Honda (FCX Clarity), 2 cars Mazda (Ice, RX 8 Hydrogen), 1 car Toyota Prius one visit For 700 bar dispenser Opel/GM Hydrogen 4, 1 car B-class F-Cell Daimler, extensive testing with a few cars IR Communication, SAE Release A Standard 3 min. for 4 kg, aiming at 100% fill rate Some other Customers Rastogi / Lienkamp

  25. Assessment Framework • INPUT DATA • Data tables on • Infrastructure • Vehicles • 2 Demo. sites • OEM‘s and Operators • Results • Indicators on • Infrastructure • Vehicles • 2 Demo. sites • Indicator value (0 to 1) Simple Data Processing • Compare with Ref. Technology • Technological aspects: • Performance, Environment, Safety • Socio-Economy • Project Organisation Rastogi / Lienkamp

  26. Data Assessment Rastogi / Lienkamp

  27. Comparison F-Cell Vs. Diesel Rastogi / Lienkamp

  28. Summary of 2 years • 3-7 FCV‘s, 100 vehicle months of operation, over 45000 km driven (should have been more) • over 510 kg. H2 consumed, 7.2 tons of CO2 emission saved • Vehicles showed high reliability and availablity (98%) • Availability 350 bar dispenser 95% • Availability 700 bar dispenser 55% (accident costed 11 months) • Ionic compressor 77% (has been overhauled) • By-product hydrogen should be exploited more initially • Infrastructure problems experienced are not related to H2 Rastogi / Lienkamp

  29. Some Lessons Learnt • Serious problems with approval formalities in Italy • Delay in infrastructure construction • Fleet is still operated at 200 bar storage • European Harmonisation, Integrate authorities in project • Bottle neck for larger demonstrations • Fleet availability (cost), not so much infrastructure • Frankfurt station can fill 15 FCV‘s /hour • By-product Hydrogen should be exploited much more Rastogi / Lienkamp

  30. Concluding Remarks • H2-infrastructure developed and FCV fleet used in Zero Regio Project have been briefly presented • Operational experience has been encouraging at both sites • FCV-Fleet has operated better than expected • Fuel consumption of FCV is about half of NGV • Fast refuelling of 700 bar FCV‘s has been realised • Zero Regio high potentials: HP-Pipeline transport,700 refuelling with IR communication. Thank You • Final Conference at WHEC 2010, Essen, Germany. Rastogi / Lienkamp

  31. H2 Service Station Mantova Area = 17.000 m2 350 bar GH2 Photovoltaic 16 kW Opened on 21.09.2007 Rastogi / Lienkamp

  32. Hydrogen Dispenser - Mantova GH2 350 bar Rastogi / Lienkamp

  33. Onsite H2 Production Plant Rastogi / Lienkamp

  34. F-Cell A-Class Vehicle type: Mercedes-Benz A-Class Fuel-Cell system: PEM, 72 kW (97 PS)Electro-Asynchron-MotorMotor rating: 65 kW (87 PS)Max. Torque: 210 NmFuel: Hydrogen (350 bar)Range: 160 kmMax. Velocity: 140 km/h Battery: NiMh, air-cooledPower (av./peak): 15 kW / 20 kW Rating: 6,5 Ah; 1,4 kWh Rastogi / Lienkamp

  35. 1 2 3 4 5S SOCIO-ECONOMIC STUDIES Rastogi / Lienkamp

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