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Heinrich Lienkamp, Ashok Rastogi Infraserv Höchst - Frankfurt Germany

Heinrich Lienkamp, Ashok Rastogi Infraserv Höchst - Frankfurt Germany

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Heinrich Lienkamp, Ashok Rastogi Infraserv Höchst - Frankfurt Germany

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  1. Demonstration of Fuel-Cell Vehicles in European Cities Heinrich Lienkamp, Ashok Rastogi Infraserv Höchst - Frankfurt Germany www.zeroregio.com Rastogi

  2. Outline Brief presentation of 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 Performance & Environmental aspects Concluding Remarks; Next steps Rastogi

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

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

  5. H2 - Infrastructure in Germany Hydrogen center in Industry park, Höchst Existing infrastructure Bi-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

  6. Lay out HP Pipeline in Höchst Rastogi

  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

  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

  9. Ionic Fluid Compressor – working principle PLC Rastogi

  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

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

  12. Service Station Frankfurt Rastogi

  13. Operational Experience in Germany On average 30 kg/month refilled (max. rate 60g/s) More milage and applications planned High availability inspite of some teething problems: Filters in the cooling system of the compressor Some valves failed on the compressor system Some loose fittings leading to system failure 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

  14. Operational Experience in Germany Rastogi

  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

  16. Servicestation Mantova Rastogi

  17. 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

  18. 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

  19. Beauty and the Beast F-Cell serving A-380 !! Rastogi

  20. 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

  21. 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

  22. Data Assessment Rastogi

  23. Comparison F-Cell Vs. Diesel Rastogi

  24. 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

  25. 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 • For better mileage 700 bar storage is necessary • Fuel consumption of FCV is about half of NGV • Fast refuelling of 700 bar FCV‘s has been realised • Pipeline transport is high potential of the project • Thank You See you at WHEC 2010 & ZERO REGIO final conference Rastogi

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

  27. 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 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

  28. Hydrogen Dispenser - Mantova GH2 350 bar Rastogi

  29. Onsite H2 Production Plant Rastogi