BMW EfficientDynamics: Cryo-compressed H2-Storage for Less Emissions, More Driving Pleasure

1. BMW Hydrogen. NHA Hydrogen Conference 2010. BMW EfficientDynamics Less emissions. More driving pleasure. Cryo-compressed H2-Storage – A Promising Candidate to Supplement the Vehicle Storage Portfolio. Dr. Klaas Kunze. 4th of May 2010, Long Beach.

2. BMW Cryo-compressed hydrogen storage.Outline. • BMW hydrogen strategy • Infrastructure aspects • Cryo-compressed hydrogen vehiclestorage • Outlook andconclusion

3. BMW Efficient Dynamics Hydrogen. BMW Hydrogen Strategy. Hydrogen 7 smallseries Advancedkeycomponents Next vehicle & infrastructure Technology leapstorage & drivetrain Advancement Storage & Drive train • Efficient long-range mobility: • High energy availability / vehicle range • Efficient drive train • Optimized safety oriented vehicle package & component integration • Loss-free operation for all relevant use cases • Fast refueling capability • Compatibility to existing infrastructure (CGH2) H2-Storage • LH2 Storage • Capacity • Safety • Boil-off loss • Pressuresupply • Complexity • Infrastructure CcH2 LH2 CGH2 Source: BMW Source: BMW Source: Dynetek H2 Drive train • V12 PFI engine • Power density • Dynamics • Durability & cost • Efficiency Fuel Cell FC-EREV FCHV EREV H2HEV Electrification H2ICE today

4. The Challenge of Vehicle Energy Storage. Fuel economy favors battery electric vehicles… Fuel Economy +65% 1.5 – 1.8 x times higher fuel economy +50% BEV FC-EREV +20% FCEV + 25% H2-ICE Hybrid H2-ICEBMW Efficient Dynamics H2-ICE Standard Technology

5. The Challenge of Vehicle Energy Storage.… but H2-storage density beats batteries. 8.9 kWh/kg 9 • System weight and volume examples: • 30 L gasoline (7.8 kg H2, 260kWh): • CcH2 : 130 kg, 245 L (next) • CGH2,700bar : 163 kg, 325 L (best) • Li-Ion: 1730 kg, 1040 L 8 6.9 kWh/L 7 CcH2 300 bar CGH2 700 bar CGH2 350 bar System energy density [kWh/kg], [kWh/L] 2.0 kWh/kg 2.0 kWh/kg 2 1.6 kWh/kg 1.2 kWh/L 0.8 kWh/L 1 0.6 kWh/L 0.25 kWh/L 0.15 kWh/kg 0 0 ambient cryogenic Hydrogen Gasoline Li-Ion Battery (second generation battery) Source: BMW for 7.8kg CcH2 and TIAX(US DOE) 2009 for 5,6 kg 350/700 bar CGH2.

6. The Challenge of Vehicle Energy Storage. … but H2-storage fill rate beats batteries. 350 CcH2* 60 CGH2 700 bar CGH2 350 bar 80 times higher fill rate 50 40 Refueling / refill rate [kWh/min] 30 • Refill rate example: • 30 L gasoline (7.8 kg H2, 260kWh): • CcH2 : 4 min • CGH2,700bar : 5 min • Li-Ion: 4 hours 20 10 0 ambient cryogenic Gasoline Hydrogen Li-Ion Battery** (Second generation battery ) *) CcH2: Cryo-compressed Hydrogen , reference system (~8 kg H2) **) 50KW/200V fast charging

7. BMW Cryo-compressed hydrogen storage.Outline. • BMW hydrogen strategy • Infrastructure aspects • Cryo-compressed hydrogen vehiclestorage • Outlook andconclusion

8. H2-Infrastructure.Infrastructure forecast Germany. • H2-Infrastructure forecast Germany: • „Cost-effectiveness, stationfootprintandsafetyissues will decide on deliverymethod und stationlayout“ •  • Liquid hydrogen distributionalonghighwaysand in remote areas • Gaseous hydrogen distribution via pipelines in metropolitanareas • Compressed gas trailersandonsiteelectrolysis in ramp-upphase, only •  • Liquid deliveryandstationstoragelikelytoplay an importantrole in futureinfrastructure Source: NOW 2010 (GermanHy,)

9. H2-Infrastructure.Filling Station with LH2-Supply today. Source Production Delivery Filling Station CGH2 High pressure compressor High pressure compressor up to 24 g/L Natural gas Carbon EU el. mix Windpower Hydropower Solar energy Geothermal energy Biomass 24 / 40 g/L CGH2 SMR Cooler 1.5 kg/min (3 MW) 350 / 700 bar GH2 Heat exchanger Electrolysis Liquefaction LH2 High operating costs – low efficiency LH2 69-65 g/L 1,5 – 3 bar 63 g/L LH2 LH2 Trailer LH2 pump Return gas LH2 Filling station storage 1 kg/min (2 MW) 4 bar

10. H2-Infrastructure.Fillingstationwith LH2-supply and CcH2. Source Production Delivery Fillingstation High efficiency, lower operating costs and cryo-compressed fuel option with highest density CGH2 Natural gas Carbon EU el. mix Windpower Hydropower Solar energy Geothermal energy Biomass SMR 24 / 40 g/L CGH2 After cooling 1.5 kg/min (3 MW) CcH2 350 / 700 bar GH2 Partial warm-up 80 g/L CcH2 Electrolysis Liquefaction LH2 2 kg/min (4 MW) Cryogenic high- pressure pump 300 bar LH2 69-65 g/L 1,5 – 3 bar 63 g/L LH2 LH2 Trailer LH2 pump Return gas LH2 Filling station storage 1 kg/min (2 MW) 4 bar

11. H2-Infrastructure. Cryogenic high pressure pump.

12. BMW Cryo-compressed hydrogen storage.Outline. • BMW hydrogen strategy • Infrastructure aspects • Cryo-compressed hydrogen vehiclestorage • Outlook andconclusion

13. 80 g/L LH2 – 1 bara CcH2 – 300 bar / 38 K 63 g/L CGH2 – 350 bar / 288 K CGH2 – 700 bar / 288 K 40g/L 33 K -40°C BMW Cryo-compressed Hydrogen Storage.CcH2 – denserthan LH2. cryogenic compression +27% 880 bar x2 700 bar LH2 – 4 bara 500 bar 350 bar Density [g/L] 250 bar LH2 150 bar CcH2 12,84 bar CGH2 20 bar 4 bara Temperature [K]

14. CGH2 700 bar LH2 2-10 bar Loss-free operation in typical usage + Boil-off loss - System volume - High storage capacity + Dormancy, autonomy - Fiber cost Pressure supply for ICE-ATL / FC - + Insulation complexity - Low adiabatic expansion energy + System weight - Hybrid use - CGH2 refueling option Two-phase issues + - Warm refueling time - Simplified Superinsulation Lightweight Vacuum Shell Carbon overwrapped Pressure Vessel (Type 3) BMW Cryo-compressed Hydrogen Storage. Concept. + „Insulate a pressure vessel with a simplified superinsulation, fill with compressed cryogenic hydrogen and operate in the cryo-compressed gas region” Simplify insulation (10W  2W) Reduce pressure (700 bar  350 bar) CcH2 20-350 bar

15. BMW Cryo-compressed Hydrogen Storage.EnergyDensity. • Highestrangeatlowestfuelcost: • Long range CcH2-mode • City gas mode (CGH2 350bar) • „Alwaysthemostconvenient H2-fuel“ 265 kWh CcH2 – mode +50% CGH2 – mode 260 kWh Volumetric system energy density [kWh/L] +50% Gravimetric system energy density [kWh/kg]

16. BMW Cryo-compressed Hydrogen Storage.Safetyaspects. Vacuumenclosure & safetyreleasecontrol Coldrefueling & lowadiabaticexpansionenergy Redundant safety devices Ambient CGH2 storage after refueling CcH2 Vacuum enclosure 6-15 times lower expansion energy Adiabatic expansion energy [kWh/kg] Full CcH2 storage after cold refueling COPV in vacuum environment CcH2,250bar, 48K CGH2,700bar, 350K LH2, 4bara, (26K) CGH2,700bar, 288K CGH2,350bar, 350K CcH2,300bar, 80K • Vacuumenclosure designlowersriskofpressurevesseldamage (mechanicalandchemicalintrusion, bonfiredamagingandaging) andenablesleakmonitoring. • Redundant safetydevicesforsafe hydrogen release in caseofdamage / vacuumfailure. • Cryogenic hydrogen contains a fairlylowadiabaticexpansionenergyand thus, can mitigate implications of a sudden pressure vessel failure, in particular during refueling.

17. BMW Cryo-compressed Hydrogen Storage. System layout – BMW prototype 2011. + Active pressure control + Optimized vehicle body integration + Engine/Fuel cell waste heat recovery MLI insulation (in vacuum space) COPV (Type III) Shut-off valves Refueling line Vacuum enclosure (Aluminum) Coolant heat exchanger Intank heat exchanger Aux. systems (control valve, regulator, sensors) Secondary vacuum module (shut-off / saftey valves)

18. BMW Cryo-compressed hydrogen storage.Outline. • BMW hydrogen strategy • Infrastructure aspects • Cryo-compressed hydrogen vehiclestorage • Outlook andconclusion

19. BMW Cryo-compressed Hydrogen Storage.Development plan. Technology milestone 2007 2008 2009 2010 2011 2012 2013 2014 Conceptmilestone Concept phase & pretests Componentmilestone Component qualification Concept Vehicle storage BMW Proof of concept prototype Prototype development BMW + 12 partners Demonstrator vehicle Vehicle application BMW + Linde LH2cryopump CcH2 – demorefueling device Infrastructure BMW & partners CcH2 – prototype fillingstation

20. Hydrogen is a promising alternative fuel for efficient zero emission long range mobility and complements battery electric mobility. Cryo-compressed hydrogen (CcH2) storage has been identified as a promising candidate to overcome limits of LH2 storage and combines the advantages of gaseous (CGH2) and liquid (LH2) storage. Cryo-compressed hydrogen storage takes advantage of LH2-based infrastructure and is compatible to 350 bar GH2 infrastructure. BMW is on the way to a first automotive CcH2 storage prototype to be presented in 2011. BMW Efficient Dynamics Hydrogen.Conclusion.

22. Cryo-compressed „CcH2*“ source: BMW 5kg - 12kg insulated cryogenic pressure vessel BMW Cryo-compressed Hydrogen Storage. Automotive hydrogen storage options. Physical Storage Solid storage Compressed Liquid Hydrides Adsorption „LH2*“ „CGH2*“ „metallic“ „activated carbon“ source: Dynetek source: BMW „chemical“ „MOFs“ 1kg - 6kg single or multi-bottle pressure vessel 8kg - 12kg insulated conformable or cylindrical cryotank „organic“ „Zeolith“ Small series demonstration level > 10 OEM Small series demonstration level BMW Prototype development by BMW & partners Research level! *) CGH2 := Compressed Gaseous Hydrogen (350/700bar) CcH2:= Cryo-compressed Hydrogen ( 350bar) LH2 := Liquid/Liquefied Hydrogen (1bara - ca. 10bara)

23. Ttank ptank pmin BMW Cryo-compressed Hydrogen Storage.Activepressurecontrol. Receptacle and filling hose Coolant heat exchanger Pressure-limiting device Pressure control unit Secundary vacuum modul (cold valves) Outer tank (light weight, metal) Superinsolation (simplified) Cryogenic pressure vessel (Type 3)

24. BMW Cryo-compressed Hydrogen Storage. Single flowrefuelling – from warm tocold. Storage density when switching from warm (CGH2) to cold (CcH2)  long dist. travel. Simulation results for reference system, highway consumption 2,0 kg H2/100km (luxury class sedan) max. density Start with warm storage (after several CGH2 refuellings) 4.Reflg. H2-storage density [g/L] 3.Reflg. Driving 2.Reflg. 1.Refuelling Refill (at 80km remaining range) Storage temperature [K]

25. Loss-free CGH2 density 24 g/L 24 g/L LH2: 150 L, 3.5 W at 25 g/L CcH2: 150 L, 7 W at 36 g/L CcH2: 150 L, 7 W at 72 g/L DQ = 150x0.016 = 2.4 Wdays Q (mean heat leak): 3.5 W Dt(loss-free dormancy time): =DQ/Q ~17 h DQ = 150x0.66 = 99 Wdays Q (mean heat leak): 7 W Dt(loss-free dormancy time): =DQ/Q ~14 days DQ = 150x0.16 = 23 Wdays Q (mean heat leak): 7 W Dt(loss-free dormancy time): =DQ/Q ~3.3 days CcH2 250 bar, 48K BMW Cryo-compressed Hydrogen Storage. CcH2 storage: higher heat receptivity than LH2. CcH2 storage can beat heat receptivity of LH2 storage by a factor of 5-20. Heat receptivity* [Wdays/L**] Density [g/L] *) equilibrium hydrogen **) 1 Wday/L = 1 day loss-free dormancy time per Watt heat leak and L net fuel volume.

26. 10:1 5:1 BMW Cryo-compressed Hydrogen Storage. CcH2 storage: lower vent rates than LH2. CcH2 vent rates per Watt heat leak are potentially 5-10 times lower than boil-off rates per Watt heat leak in LH2 storage systems. Vent rate at release pressure* [g/h/W] Density [g/L] *) equilibrium hydrogen

27. H2-Infrastructure.Fillingstationconceptscomparison. 400 kg CGH2 1000 kg LH2

28. H2-Infrastructure. Energydemand H2-compression andcooling. 2500 Re-cooling Compression CGH2 -Delivery LH2-Delivery with cryogenic pump 2000 1500 Energy demand normalized to CcH2 [%] 1000 500 0 CGH2 700 bar CGH2 350 bar CGH2 700 bar CGH2 350 bar CcH2 300 bar

29. The Challenge of Vehicle Energy Storage. … but hydrogen storage costs beat batteries. 500 max min System cost 250 • System cost example: • 30 L gasoline (7,8 kg H2, 260kWh): • CcH2 : 2400 - 4400 € • CGH2,700bar : 3900 - 5400 € • Li-Ion: > 65.000 € 15-30 times lower system cost 30 CGH2 700 bar CGH2 350 bar 20 System cost* [€ / kWh] CcH2** 10 0 0.15 kWh/kg cryogenic ambient Gasoline Hydrogen Battery (High-energy Li-Ion) *) at > 100.000 u/a **) CcH2: Cryo-compressed Hydrogen, reference system (~8 kg H2) Source: BMW and TIAX(US DOE) 2009.