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High-Pressure Hydrogen Storage

Systems

Presented byQuantum Fuel Systems Technologies

Worldwide, Inc.

Hydrogen and Fuel Cell Summit VIII

June 15-17, 2004

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Making the Hydrogen Economy a Reality

Automakers need Hydrogen storage solution

Assurances that refueling infrastructure will bethere

Suppliers need

Production volume to reduce costs througheconomies of scale Demand sufficient to justify capital expenditures Consistent, performance-based codes and

standards Consumers need

Vehicles that are transparent to own and operate Convenient refueling and cost-competitive fuel

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Hydrogen Storage Its More Than a Tank

Hydrogen storage systems on H2 vehicles must:

Contain

Control Regulate

Monitor Distribute Meter Refill Survive

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Integrated Fuel Storage Systems

FUEL STORAGESYSTEMS

TANK

IN-TANK REGULATOR

W/ PRD, TEMP &

PRESSURE SENSORS

SOLENOIDS

VALVESFUEL LINES /

TUBINGELECTRONICS

SUPPORT

STRUCTURE /

BRACKETRY

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Storage

Fuel LinesInjection / Metering

OEM Production Level Integration

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Quantum TriShieldTM Storage Tank

In-Tank Regulator

Pressure Sensor

(not visible here)

Pressure Relief Device (thermal)

In-Tank GasTemperatureSensor

High Molecular Weight Polymer Liner (gas barrier)

Carbon Composite Shell (structural)

Protection Layer (damage resistant)Foam Dome (impact protection)

Gas Outlet Solenoid

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100

125

150

175

200

225

250

350 400 450 500 550 600 650 700

Pressure (bar)

RequiredStora

geVolume(liter)

0.02

0.025

0.03

0.035

0.04

0.045

0.05

HydrogenD

ensity(kg/liter)

Hydrogen Energy Density

Compression Energy vs. Storage Pressure

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

0 100 200 300 400 500 600 700 800 900 1000

Pressure (bar)

E

nergykJ/kg@3

00k 12% Increase

Hydrogen Density as a Function of Pressure (@

288 K)

0

10

20

30

40

50

60

70

0 200 400 600 800 1000 1200

Bar

kg/m3

Ideal Gas RedlichKwong

Anghaie

350 bar vs. 700 bar Storage

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Tank Validation

StoragePressure

StandardsCompliance

3,600 psi

(25 MPa)

NGV2-2000 (modified)

DOT FMVSS 304(modified)

5,000 psi

(35 MPa)

E.I.H.P. / GermanPressure Vessel CodeDBV P.18NGV2-2000 (modified)

FMVSS 304 (modified)

KHK

10,000 psi

(70 MPa)

E.I.H.P. / GermanPressure Vessel CodeDBV P.18

FMVSS 304 (modified)

Hydrostatic Burst Extreme Temperature Cycle

Ambient Cycle Acid Environment Bonfire Gunfire Penetration

Flaw Tolerance Accelerated Stress Drop Test

Permeation Hydrogen Cycle Softening Temperature Tensile Properties

Resin Shear Boss End Material

Validation Tests

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In-Tank High Pressure Regulator

Patented technology Natural Gas or H2 Eliminates need for

high pressure fuel linesin the vehicle

Multi-functional designsimplifies integration

In-Tank Regulator Validation - Hydrogen

5000 psi: NGV3.1, EIHP, KHK Japanese High Pressure Vessel Code

10,000 psi: TV German Pressure Vessel Code

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In-Tank Regulator Features

1 or 2 stages of pressureregulation

Thermally activated pressurerelief device (PRD) (non-resetting)

Pressure activated PRD (self-resetting)

Electrically controlled shut-offvalve

Manual pressure shut-off valve

Pressure sensor

Internal temperature sensor

Inlet check valve Excess flow valve

High pressure inlet fill fitting

Regulated pressure outlet fitting

Captured relief vent port

Parameter Nominal Performance

Minimum inlet pressue 20 bar

Maximum inlet pressure 856 bar at 85 C

Nominal outlet pressure 10.2 bar Nominal hydrogen flowrate 1.63 g/sec

Proof pressure 1027 bar

Burst pressure 1517 bar Low pressure relief 15.9+1.4/-0.7 bar

Cracking pressure droop 0.55 bar

Dynamic pressure droop 0.0017 bar/slpm

Operating temperature -40 C to + 85 C

Hydrogen response rate up to 1 g/sec in

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Application ExamplesApplication Examples

H d i S t F

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Hyundai Santa Fe 5,000 psi (35 MPa) H2 storage system

Scope of Work:Components & SubsystemsAll-composite Hydrogen Fuel TankPressure RegulationFuel Lines and FittingsWire Harness

System Packaging & Integration

GM H d G 3 C d 700

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GM HydroGen3 Compressed 700

Scope of Work:

Components & SubsystemsAl l-composite Hydrogen Fuel TankPressure RegulationFuel Lines and FittingsWire Harness

System Packaging & Integration

H d F l S S

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Hydrogen Fuel Storage System

70 MPa Composite

Tanks

Vent LinePorts

Defueling Port(optional)

Refueling Port

FilterCheck Valve

Vehicle Interface Bracketwith Stone Shield

In Tank Regulatorwith Solenoid

GM H d G 3 C d 700

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GM HydroGen3 Compressed 70010,000-psi (70 MPa) Hydrogen Fuel Storage System

GM Hy wire

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GM Hy-wire5,000-psi (35 MPa) Hydrogen Fuel Storage System

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Compressed Hydrogen Storage Safety

Compressed Gases are All Around Us

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Compressed Gases are All Around Us

Industrial gas 6,000

Firemans breathing tank 4,500

Paintball propellant 4,500Natural gas vehicle storage 3,600

Scuba tanks 3,300

Medical 3,000

Aircraft oxygen andemergency slides 3,000

Beverage 1,800

Nitrous Oxide (automotive) 1,200Fire extinguishers 240

Applications Service Pressures

(psi)

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Validation Testing

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Validation Testing

Gunfire Testing

Burst Testing

Hydrogen Cycling

Environmental

Testing

Bonfire Testing

Severe Abuse Testing

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Severe Abuse Testing

Hydrogen vs Gasoline

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Hydrogen vs. Gasoline

From: M. Swain

Hydrogen Safety

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Hydrogen Safety

Current designs are based on decadesof industrial experience with

compressed gases and hydrogen Government and industry groups are

developing standards

Performance-Based Safety StandardsWill Ensure Safe Hydrogen Storage and

Handling

Performance-Based Safety StandardsWill Ensure Safe Hydrogen Storage andHandling

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