- Email: [email protected]
Sandia project to speed up refueling of hydrogen forklifts
NEWS now available for sale to professional and military customers. UltraCell also says that its XX55™ reformed methanol fuel cell (RMFC) product has exceeded US Air Force requirements for MTBF (mean time before failure) and cycling. UltraCell has just completed a 30-month development period which included field testing in Arctic and desert conditions with partner customers and extensive laboratory testing at temperatures ranging from –20°C to +50°C and aggressive MIL-STD (US military standard) tests. The Blade portable fuel cell system is optimised for compact size, at just 33.5 × 24.9 × 19.0 cm, while also being packaged into a MIL-STD chassis. Designed from the start with ‘silent watch’ applications in mind, the system is whisper quiet at less than 40 dB. It includes an internal BrenTronics BB2590/U battery for surge capability, and the fuel cell can be set to automatically turn on and off based on the internal or external battery voltage. The unit can also function with other hybrid batteries. It comes in two versions: a 50 W system, and a variable output power platform (0 to 165 W) that can be specified by the customer at the time of purchase, with standard power options of 75, 100, and 150 W. The Blade industrial design is optimised for maintainability, with internal components easily swapped out to allow for long-term service life. Major elements are sized for >2000 h lifetime, and certain critical components have demonstrated 8000 h lifetime. The Blade is a higher power version of UltraCell’s 55 W XX55 fuel cell, which was originally developed with funding from the US Air Force Research Lab (AFRL) [FCB, October 2013, p5]. Over the last three years UltraCell, as part of Bren-Tronics [FCB, August 2011, p5], has continued to refine and improve the product. The XX55 recently exceeded all AFRL durability requirements for lifetime and cycling, as well as other MIL-STD requirements such as shock and vibration, electromagnetic interference (EMI) etc. The XX55 was designed primarily to support dismounted soldiers by powering highenergy devices such as rugged computers, manpack radios, and other gear. UltraCell, Livermore, California, USA. Tel: +1 925 455 9400, www.ultracell-llc.com
FUELING
Sandia project to speed up refueling of hydrogen forklifts
A
partnership between Sandia National Laboratories in
6
Fuel Cells Bulletin
Livermore, California and Hawaii Hydrogen Carriers (HHC) in Honolulu aims to boost the use of solid-state hydrogen storage with fuel cell systems for powering forklifts at lower cost and with faster refueling. The project will design a metal hydride storage system that can refuel at low pressure (e.g. 35 bar, 500 psi) four to five times faster than it takes to charge a battery forklift, according to Joe Pratt, Sandia’s project manager. Pratt has spearheaded other Sandia efforts to introduce hydrogen systems, and recently led a study [FCB, May 2013, p11] and subsequent demonstration project on the commercial use of hydrogen fuel cells to provide power at ports [FCB, March 2014, p7]. Standards developed by Sandia will be published shortly (such as CSA HPIT 1), helping industry to develop new, high-performance hydrogen fuel systems for industrial trucks [see the forklift features in FCB, September and October 2010]. Sandia is also involved in the new H2FIRST project to accelerate the rollout of hydrogen fueling infrastructure [see page 7]. HHC has now obtained a grant from the Department of Energy’s Fuel Cell Technologies Office, to develop a low-pressure hydrogen storage system that can be refueled at standard industrial gas pressures. This should reduce fuel system cost, and expand the market to facilities that cannot accommodate conventional highpressure (350 bar, 5000 psi) fueling systems. Designing a storage system that meets HHC’s specifications and can be integrated into a fuel cell power pack had to overcome some key challenges, including identifying optimal metal hydride materials, determining an optimal shape and size for the storage tank, and ensuring thermal management to achieve and maintain the temperatures required for fast refueling and hydrogen supply. Work to identify the best metal hydride for the system focused on Hy-Stor 208, a Mischmetal-nickel-aluminium alloy that meets targets for hydrogen storage capacity, density, and thermal conductivity. The material also provides sufficient hydrogen pressure for refueling at an operating temperature of 60°C. While this type of metal hydride is heavy, the weight acts as necessary ballast and thus is a benefit in forklifts. To increase thermal conductivity, the team explored adding to the metal hydride two forms of expanded natural graphite, flakes and tubular ‘worms’. The team has developed an optimised storage-system design, and also begun to conceive of a tube array that would allow efficient thermal management, via water flows around the tubes. With the Sandia–HHC design work complete, project activity will
transfer to Hawaii, where HHC will produce the first prototype metal hydride storage system. HHC will work with Canadian company Hydrogenics, which will integrate the new storage system into its PEM fuel cell power pack, designed to fit into a forklift. Contact: Dr Joe Pratt, Sandia National Labs, Livermore, California, USA. Tel: +1 925 294 2133, Email: [email protected] Sandia National Labs, Hydrogen Research: http://tinyurl.com/sandia-crf-h2 Hawaii Hydrogen Carriers: www.hawaiihydrogencarriers.com CSA HPIT 1 standard: www.fuelcellstandards.com/CSA%20HPIT1.htm DOE Fuel Cell Technologies Office: www.eere.energy.gov/hydrogenandfuelcells Hydrogenics: www.hydrogenics.com
Continuing HyTEC progress in London for hydrogen fueling
I
n the UK, Air Products’ HyTEC hydrogen refueling station at Hatton Cross, near Heathrow Airport, will be upgraded to 700 bar (10 000 psi) fast-fill by early summer, in preparation for the arrival of the first OEM passenger cars in London. The HyTEC project is creating two new European hydrogen passenger vehicle deployment centres in London and the Danish capital Copenhagen. The Hatton Cross hydrogen station is strategically located near a number of major roads (M3, M4, M25), and adjacent to the UK’s busiest airport. This station is expected to play a key role in supporting the continued uptake of hydrogen-fueled vehicles in and around London. HyTEC is also supporting work to define optimal locations of the next wave of hydrogen refueling stations in and around London as part of a coherent hydrogen transport rollout strategy for the capital [see the Air Products feature in FCB, February 2013]. FCEV deployment in London under HyTEC is expected to continue in 2014, with a pair of Hyundai ix35 FCEVs due to arrive later in the year, for use in daily operations by Transport for London. The Greater London Authority is working closely with Hyundai Motor UK to identify additional vehicle end-users. London is one of five European cities that will demonstrate a total of 110 FCEVs through the HyFIVE project [FCB, April 2014, p1], which is partfunded by the Fuel Cells and Hydrogen Joint Undertaking (FCH JU), with 75 of these vehicles coming from Korean automaker Hyundai.
May 2014
FUELING
Sandia project to speed up refueling of hydrogen forklifts
A
partnership between Sandia National Laboratories in
6
Fuel Cells Bulletin
Livermore, California and Hawaii Hydrogen Carriers (HHC) in Honolulu aims to boost the use of solid-state hydrogen storage with fuel cell systems for powering forklifts at lower cost and with faster refueling. The project will design a metal hydride storage system that can refuel at low pressure (e.g. 35 bar, 500 psi) four to five times faster than it takes to charge a battery forklift, according to Joe Pratt, Sandia’s project manager. Pratt has spearheaded other Sandia efforts to introduce hydrogen systems, and recently led a study [FCB, May 2013, p11] and subsequent demonstration project on the commercial use of hydrogen fuel cells to provide power at ports [FCB, March 2014, p7]. Standards developed by Sandia will be published shortly (such as CSA HPIT 1), helping industry to develop new, high-performance hydrogen fuel systems for industrial trucks [see the forklift features in FCB, September and October 2010]. Sandia is also involved in the new H2FIRST project to accelerate the rollout of hydrogen fueling infrastructure [see page 7]. HHC has now obtained a grant from the Department of Energy’s Fuel Cell Technologies Office, to develop a low-pressure hydrogen storage system that can be refueled at standard industrial gas pressures. This should reduce fuel system cost, and expand the market to facilities that cannot accommodate conventional highpressure (350 bar, 5000 psi) fueling systems. Designing a storage system that meets HHC’s specifications and can be integrated into a fuel cell power pack had to overcome some key challenges, including identifying optimal metal hydride materials, determining an optimal shape and size for the storage tank, and ensuring thermal management to achieve and maintain the temperatures required for fast refueling and hydrogen supply. Work to identify the best metal hydride for the system focused on Hy-Stor 208, a Mischmetal-nickel-aluminium alloy that meets targets for hydrogen storage capacity, density, and thermal conductivity. The material also provides sufficient hydrogen pressure for refueling at an operating temperature of 60°C. While this type of metal hydride is heavy, the weight acts as necessary ballast and thus is a benefit in forklifts. To increase thermal conductivity, the team explored adding to the metal hydride two forms of expanded natural graphite, flakes and tubular ‘worms’. The team has developed an optimised storage-system design, and also begun to conceive of a tube array that would allow efficient thermal management, via water flows around the tubes. With the Sandia–HHC design work complete, project activity will
transfer to Hawaii, where HHC will produce the first prototype metal hydride storage system. HHC will work with Canadian company Hydrogenics, which will integrate the new storage system into its PEM fuel cell power pack, designed to fit into a forklift. Contact: Dr Joe Pratt, Sandia National Labs, Livermore, California, USA. Tel: +1 925 294 2133, Email: [email protected] Sandia National Labs, Hydrogen Research: http://tinyurl.com/sandia-crf-h2 Hawaii Hydrogen Carriers: www.hawaiihydrogencarriers.com CSA HPIT 1 standard: www.fuelcellstandards.com/CSA%20HPIT1.htm DOE Fuel Cell Technologies Office: www.eere.energy.gov/hydrogenandfuelcells Hydrogenics: www.hydrogenics.com
Continuing HyTEC progress in London for hydrogen fueling
I
n the UK, Air Products’ HyTEC hydrogen refueling station at Hatton Cross, near Heathrow Airport, will be upgraded to 700 bar (10 000 psi) fast-fill by early summer, in preparation for the arrival of the first OEM passenger cars in London. The HyTEC project is creating two new European hydrogen passenger vehicle deployment centres in London and the Danish capital Copenhagen. The Hatton Cross hydrogen station is strategically located near a number of major roads (M3, M4, M25), and adjacent to the UK’s busiest airport. This station is expected to play a key role in supporting the continued uptake of hydrogen-fueled vehicles in and around London. HyTEC is also supporting work to define optimal locations of the next wave of hydrogen refueling stations in and around London as part of a coherent hydrogen transport rollout strategy for the capital [see the Air Products feature in FCB, February 2013]. FCEV deployment in London under HyTEC is expected to continue in 2014, with a pair of Hyundai ix35 FCEVs due to arrive later in the year, for use in daily operations by Transport for London. The Greater London Authority is working closely with Hyundai Motor UK to identify additional vehicle end-users. London is one of five European cities that will demonstrate a total of 110 FCEVs through the HyFIVE project [FCB, April 2014, p1], which is partfunded by the Fuel Cells and Hydrogen Joint Undertaking (FCH JU), with 75 of these vehicles coming from Korean automaker Hyundai.
May 2014