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Battelle completing multi-year safety testing program for compressed hydrogen storage systems for vehicles
16 July 2012
Battelle is wrapping up a multi-year safety testing program—including the development of test methods and then conducting the safety tests—for 350 bar and 700 bar hydrogen storage systems for use in vehicles. Battelle won a competitive bid contract in 2008 for the program from the US Department of Transportation’s National Highway Traffic Safety Administration (NHTSA).
Battelle has for decades served as an integral resource for developing safety test methods for new vehicle technology; the institute provides NHTSA data and information that the agency can use to establish the federal motor vehicle safety standards for new vehicles, said Dr. Denny Stephens, Research Leader for Integrated Vehicle and Transportation Systems at Battelle, who led and managed the team on the hydrogen testing project.
Results from Battelle safety testing on hydrogen vehicle fuel systems are expected to confirm that hydrogen fuel containers are rugged and robust, capable of maintaining structural integrity even in severe crashes and capable of remaining leak tight. The results will be handed over to NHTSA for their consideration, said Stephens, and will flow into the agency’s regulatory development process for upcoming hydrogen-fueled vehicles.
Testing was performed at Battelle’s High Energy Research Laboratory in West Jefferson, Ohio, as well as at vehicle crash facilities in Texas and Ohio.
In the tests that we’ve performed—and this is crash tests of some mockup hydrogen vehicles as well as crash tests of actual hydrogen fuel cell vehicles—in all cases the container, the tank and the fuel system remained leak tight. This was despite impacts to the tank itself, in crashes rear and side up to 40 mph. So this was impacts to the fuel tank region. The tanks were well protected—the vehicle provides substantial protection. Then, the tanks, being high pressure tanks, are extremely robust in a crash scenario. In addition, there is plumbing and the fittings that convey the gas. Those were deformed substantially. They are very ductile and can accommodate the deformation that occurs in a crash without leakage.
—Dr. Denny Stephens
Stephens said that the Battelle team also found that some common assumptions concerning small hydrogen leaks were not correct. Tests suggest that hydrogen from very small leaks does not disperse evenly, thereby allowing flammable concentrations to form when conventional wisdom suggests it is safe.
An additional significant finding was the indication that hydrogen permeation appears to increase flammability of interior vehicle fabrics, increasing propensity for secondary fire after hydrogen ignition.
We did show in some tests that measures needs to be taken to ensure that hydrogen does not accumulate in the passenger compartment. That it should not be allowed to accumulate by either not allowing a leak, or by providing an external means to ensure that it would be rapidly evacuated from the passenger compartment.
—Dr. Denny Stephens
Battelle test results suggest that, with appropriate safety testing, hydrogen vehicles can be as safe as conventional vehicles on the road today.
Other hydrogen systems. It can take two to five years to establish test methods for a new technology, depending upon who is involved, and their particular schedule, Stephens said. Although the Battelle team has not investigated solid-state hydrogen storage systems yet, Stephens made a few observations on the prospect.
Usually when you look at a new technology, you look at existing standards and verify the performance-based elements of them in terms of safety. At a high level, maybe 25-50% [of the work done on compressed hydrogen storage] might be applicable [for solid state systems], but then you have to get into specifics for the particular element. We looked at the failure mode and effects of high pressure hydrogen, we would look at what would be the failure modes for solid state systems.
One of the important elements in any of these systems is the vehicle duty cycle—the service environment for the vehicle. That’s basically how many refueling cycles it will go through, and what are the extremes of service—very hot days in Arizona, versus very cold days in Alaska—and looking at that range of conditions and then defining the engineering duty cycles which basically sets the operating range for the performance of the system. That’s one element that definitely can be carried over: the service environment and duty cycle.
Part of where we’ve supported industries through the years is understanding the challenges of automotive service, heavy vehicles, trucks, transit buses, motor coaches, the rigors, and then establishing the fuel system safety requirements to ensure that these system can operate safely throughout their design service life through real world environments.
—Dr. Denny Stephens
July 16, 2012 in Hydrogen Storage, Safety | Permalink | Comments (6) | TrackBack (0)
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Is it time to begin hydrogen commercialisation ? What more they need to study before beginning to sale to consumers some hydrogen. Petrol and ice engines is making a trillion dollars sale each year. Logically we can observe that there is a commercial opportunity in doing a product that compete gasoline-diesel. The economy is supposed to offer for sale products that are better so consumers will buy. If there is not yet any hydrogen products for sale anywhere the logical reason
is that hydrogen have been bought by ice and petrol cartel that do not want to lose money from their lucrative business. Also the few hydrogen proponents are already the ones that are doing ice and petrol business like honda with their clarity or many hydrogen fuelcell prototype from mercedes and gm, etc. And for the hydrogen fuel we have shell hydrogen and chevron hydrogen. To date any of these chaps just did some patents without any hint of a commercialisation. Logically we should have seen some commercialisation from commercial entities that are not doing petrol or ice commercialisation so they do not have incentives to not sale hydrogen products.
This study should help some business to begin to devellop this new promising business opportunity. What other reasons do they need. I said many time that im interrested to buy, so bring the product and put it for sale. What im looking for is a small hydrogen fuelcell car with a unit of production of hydrogen installed into the car so there is no need to have an external hydrogen pump for the car. Just put a small water electrolyzer into the car that do hydrogen from the water and the pure hydrogen gas is stocked into the hydrogen tank.
Posted by: A D | July 16, 2012 at 10:07 AM
I'd like to see a comparison in purchase and operating cost between a 700-bar hydrogen FCEV and a 350-bar CNG ICEV. The NGV is clean enough (except for tailpipe carbon emissions, which become irrelevant unless the H2 production system is sequestered) and there appears to be much less expense involved in the infrastructure.
Posted by: Engineer-Poet | July 16, 2012 at 12:34 PM
Good point, E-P.
Just wait until the Toyota ft-bh hybrid come out with a NG version. At well over 100 mpg, it does not need such a big NG tank like converting existing ICEV would require. Now, if the car is designed with 600 mile range on CNG tank at 5000 psi, holding an equivalent of 5-6 gallons of gasoline, the tank size would still be practical to preserve internal space.
This 600-mi range on NG will allow 200-mi range on H2 when compressed to the same 5000 psi in the same tank. The car can be designed to run on both NG and H2 with direct fuel injection using the same injector and fuel system. I predict that eventually, renewable-energy H2 will be very cheap, much cheaper than synthetic methane. So, most people will fill up for daily commute on H2 to save money, while for long trips, they will tank up on more expensive CO2-neutral synthetic methane to get 600-mi per fill-up. The wealthy who are too lazy for frequent fill-ups with H2 will choose synthetic methane instead.
Oh, BTW, I also predict that with continual worsening of global warming and climate change, fossil fuels will one day be banned, just like CFC is banned today.
Posted by: Roger Pham | July 16, 2012 at 08:57 PM
A carbon free fuel that is easier to store than hydrogen is ammonia. The volume energy density of hydrogen is one third that of natural gas methane at the same pressure. Hydrogen is so so attractive to people who refuse to learn of the high carbon cost of making it in large quantities and the cost of compression and tanks and the million dollar fuel cell.
Most travel by automobiles every day is limited to 40 miles or less on the average. This can be done with a cheap car with lead-acid batteries even, and a fuel powered range extender is always available but hardly used. All other travel can be done with "standard" high efficient ICE power with a gradual acceptance of hydraulic hybrids for double efficiency in city driving. Ian Wright says that only high mileage delivery vehicles are worth the expense of being plug in hybrids. This does not prevent wealthy people from purchasing high performance plug in hybrid electric automobiles from him as a version of performance art. ..HG..
Posted by: Henry Gibson | July 17, 2012 at 12:57 AM
@Henry,
Hydrogen is only advantageous when made from renewable energy, and only when fossil fuels are to be phased out or outright banned.
In the above scenario, then, synthetic methane or ammonia made from renewable energy are alternatives to H2, but are more expensive to make and less efficient to make. For example, to make ammonia from renewable-energy H2, the typical large-scale efficiency is around 50%. You lose 1/2 of the initial energy. Plus, you have to pay for the investment cost of the facility to make ammonia. Not cheap, and would add significantly to the cost of ammonia or synthetic methane!
Posted by: Roger Pham | July 17, 2012 at 09:50 AM
The Stranded Wind project was working on an electrolytic cell to synthesize ammonia directly from water, nitrogen and electricity, at some energy savings over production of hydrogen (ammonia synthesis from H2 and H2 is exothermic). I believe it's already been done in the lab.
Posted by: Engineer-Poet | July 17, 2012 at 04:10 PM