Report 2002 - 2007

www.cep-berlin.de 2 Foreword 3

Foreword

Just imagine … A groundbreaking project began with these ment and the leading role played by the Federal Ministry of words four years ago. It focused on a vision of a new kind of Transport, Building and Urban Affairs. We would like to mobility designed to be sustainable and emission-free express our heartfelt gratitude at this point. responsible. It aimed at providing our society with the free- dom it needs for global cooperation and also meet the chal- The Clean Energy Partnership is entering a new phase by lenges of future business and political developments. the second half of 2008. The National Organization for Hydrogen and Fuel Cells (NOW) will probably back the CEP In order to allow this vision to become reality, vehicle man- as a lighthouse project within the National Hydrogen and ufacturers, energy suppliers and the German Federal Gov- Fuel Cell Technology Innovation Program (NIP). Shell and ernment formed the Clean Energy Partnership (CEP) in 2003 the Hamburg public transport company Hamburger in line with the recommendations of the Transport Energy Hochbahn will have joined the Clean Energy Partnership in Strategy (VES).Our joint aim is to carry out tests and provide May. And consideration is being given to establishing the evidence to see whether hydrogen can fit into existing sys- first transport corridor with integrated hydrogen infrastruc- tems and be used as a fuel of the future. ture between Berlin and Hamburg.

A great deal has happened since then. The hydrogen This report on the first phase of the Clean Energy Partner- demonstration project in Berlin is one of the largest in the ship project shows you the most important milestones world. What we have achieved so far is a fleet of 17 hydro- along the pathway from a joint vision to the real world. gen cars from different manufacturers in customer hands, Emission-free mobility with hydrogen – we have already two integrated hydrogen fuelling stations to which the public covered a good deal of ground.We look forward to treading has access, buses operating within a public transit system this path together in the future. and links to the European HyFLEET:CUTE project. Many visitors from Germany and further away are proving that the CEP has already become a showcase for hydrogen technology and it has attracted a great deal of respect. New part- Yours truly, ners have joined the scheme; eleven companies are now Spokesmen for the CEP Steering Committee involved in the CEP.This would not have been possible without significant support from the German Federal Govern- Dr. Klaus Bonhoff Patrick Schnell 4 Contents 5

Contents

1 | Foreword 3 2 | Summary 6 3 | List of Abbreviations 8 4 | An Overview of the CEP 9 5.1 Our Goals… 9 5.2 … and What We Have Achieved 9 5.3 The Consortium 10 5 | The CEP in Facts and Figures 13 6 | The CEP 2003-2007: Five Years of Mobility with Hydrogen 14 6.1 Refuelling with Hydrogen 14 6.1.1 Berlin Messedamm: One of the World’s First Fully Integrated Public Hydrogen Fuelling Stations Starts Business 15 6.1.2 Berlin Heerstrasse: Energy-Optimized Refuelling 25

6.1.3 LH2 Boil-Off 29 6.2 Driving with Hydrogen 31 6.2.1 En Route:The Berlin Public Transit System Successfully Uses Hydrogen-Powered Buses on Local Passenger Routes 38 6.2.2 Reliable Mobility:The CEP Service Stations 39 6.3 Hydrogen: A Safe Fuel 40 6.4 Discovering More about Hydrogen 41 7 | The CEP after 2007 42

Visit by a Chinese delegation with Prof. Shi Doreen Krüger,Manager of the CEP TOTAL The former Federal Minister of Dinghuan, Member of the Senior Staff on the fuelling station,and TOTAL Area Manager Transport Dr.Manfred Stolpe State Council and General Secretary (retired) Uwe Wolfenstätter in March 2006,© TOTAL when the CEP Aral fuelling station of the Ministry of Science and Technology was opened on Messedamm in (MOST) of the People’s Republic of China in November 2004 April 2005 6 Summary Summary 7

2 | Summary

The Clean Energy Partnership (CEP) is an international con- gas form. Liquid hydrogen is supplied at very low tempera- for 2009, two in Berlin and one in Hamburg. In the longer sortium involving during its first phase from 2003 till 2007 tures and is stored in a separate tank.The hydrogen is used run new fuelling stations for quite a significant number of the following companies: Aral, BMW, the Berlin Public Trans- by vehicles with an internal combustion engine or a fuel cell busses both in Berlin and Hamburg will be erected.There are port Company (BVG),Daimler AG,Ford,GM/Opel,StatoilHydro, drive system. plans for a hydrogen corridor between Berlin and Hamburg Linde,TOTAL,Vattenfall Europe and Volkswagen AG. Its goal and thus the CEP becomes the most significant central is to demonstrate that the energy carrier hydrogen can be TOTAL opened the second CEP hydrogen filling station in European hub for hydrogen in transportation with links to used as a fuel in vehicles in everyday situations and it aims Berlin-Spandau in March 2006. The hydrogen plant, which the neighbouring Scandinavian Hydrogen Highway project to test the infrastructure for fuelling vehicles. has been included in a conventional TOTAL fuelling station, planned in the north.The twelve companies in the partner- provides liquid and gaseous hydrogen for cars and buses. ship from May 2008 onward – the Berlin Public Transport The first phase of the Clean Energy Partnership finished on This fuelling station also forms a link with the HyFLEET:CUTE Company BVG, BMW, Daimler, Ford, GM/Opel, the Hamburg 31 December 2007.This report provides an initial comprehen- European Hydrogen Project; the Berlin Public Transport Com- Public Transport Company Hamburger Hochbahn,Linde,Shell, sive overview of the project results that have been achieved pany (BVG) will be testing 14 hydrogen buses on normal pas- StatoilHydro,TOTAL,Vattenfall Europe und Volkswagen Group so far. In addition, it outlines the technical, political and senger operations within this project until September 2009. – comprise five automotive companies with production organizational or logistic goals of the partnership, which facilities in Germany, three of the world’s largest integrated has set a target of preparing the market for the arrival of The CEP is part of the National Sustainability Strategy and is oil and gas companies, one significant German energy hydrogen-powered vehicles by 2016. being supported by the German Federal Government. The provider,world leading companies within hydrogen produc- National Sustainability Strategy aims to demonstrate for- tion and infrastructure and two of Germany's largest public The Berlin hydrogen demonstration project is one of the ward-looking technologies and pinpoint the technical and transport companies. most significant projects of its kind in the world for testing economic conditions for using alternative fuels for road hydrogen as a fuel in a road transport context. It is the transportation. One major issue involves providing evi- largest project in Europe demonstrating the use of hydro- dence of the positive effects on the environment. This is gen as a fuel in an everyday transportation environment. why the hydrogen is produced using energy from renew- Berlin has two fuelling stations so that the approx. 17 cars able sources as far as possible. This means that virtually no driven by customers can refuel on a daily basis. The CEP is pollutants or greenhouse gas emissions are produced in the testing three different hydrogen production systems and hydrogen cycle from its production to its use. two different types of hydrogen fuel. From 2008 onward the Clean Energy Partnership will turn The CEP started its demonstration work by opening a hydro- into a true European lighthouse project,not only to become gen fuelling station that is fully integrated in a normal pub- perhaps the largest project in hydrogen transportation lic fuelling station on Messedamm in Berlin in 2004.Electroly- in Europe, but also the most complex. Apart from Berlin, sis has been used at the Aral fuelling station to produce hydrogen activities in Hamburg are included into the proj- hydrogen from water since then and it is stored in compressed ect.Currently a number of new fuelling stations are planned

Opening of the Celebration to mark “20 Years of the Federal Opening of the CEP Aral fuelling station on Visit by a Chinese delegation April 2006: Visit by Günter Dominique Perben, the French Minister of The CEP becomes a site in the “Land of Ideas” Journalists’ trip to the country CEP TOTAL fuelling station Ministry for the Environment” with Federal Messedamm with Deputy Economics Minister with Prof. Shi Dinghuan, Mem- Verheugen, EU Commis- Transportation and Infrastructure,Wolfgang project:The presentation of the prize by Thomas holding the rotating presidency on Heerstrasse in Berlin in Environment Minister Sigmar Gabriel and Georg Wilhelm Adamowitsch and Federal ber of the Senior Staff on the sioner for Enterprise and Tiefensee, the Federal Minister of Transport, Wacker, Director of Global Banking, Deutsche of the EU: Karin Roth,Parliamen- March 2006, © TOTAL Albrecht Jungk, BMW Group in June 2006 Minister of Transport Dr. Manfred Stolpe State Council and General Industry Building and Urban Affairs, and Andreas Bank Berlin, to Patrick Schnell, Manager of tary Secretary of State at the Secretary (retired) of the Mini- Sturmowski, CEO of the BVG, at the opening Sustainable Developments/New Energies at Federal Ministry of Transport, stry of Science and Technology of the CEP TOTAL fuelling station in Berlin TOTAL Building and Urban Affairs, (MOST) of the People’s Republic in March 2006. provides information about of China in April 2005 mobility in the future. 8 List of Abbreviations An Overview of the CEP 9

3 | List of Abbreviations 4 | An Overview of the CEP

BMVBS Federal Ministry of Transport, Building and Urban Affairs 4.1 | Our Goals … • The technical and economic conditions for using hydro- BSR Berlin Sanitation Department gen in road transportation have been identified and ini- BVG Berlin Public Transport Company With its roots in the Transport Energy Strategy (VES)1,the tial obstacles have been removed, CEP Clean Energy Partnership Clean Energy Partnership has set itself the goal of being the • Evidence has been provided that the production and first body to provide comprehensive evidence that it is pos- supply technologies are compatible, CGH Compressed gaseous hydrogen 2 sible for normal customers to safely use hydrogen for road • Evidence has been provided that it is quick and safe to EU European Union transportation and that even the limited renewable energy refuel vehicles with compressed gaseous hydrogen and FC Fuel cell sources available to us at the moment can be used to pro- liquid hydrogen, GH2 Gaseous hydrogen duce this fuel. • It has been proven that efficient hydrogen-powered vehi-

H2 Hydrogen cles with fuel cells and with hydrogen-powered internal HP High pressure The project aims to clearly identify and eliminate any obsta- combustion engines can be operated reliably, HyFLEET:CUTE EU Hydrogen Project (2006-2009) cles to commercialization by the start of the widespread • A vehicle service station, which meets the special require- market launch,which experts currently believe will be 2015. ments of vehicles running on hydrogen,has been designed LH Liquid hydrogen 2 and set up, LP Low pressure • Most of the hydrogen that has been used is produced LPG Liquefied petroleum gas (the LPG used in this project is pure propane) with the help of renewable energies, MoU Memorandum of Understanding 4.2 | … and What We Have Achieved • The need for further technological developments and MP Medium pressure innovations has been recognized and initial steps have NIP National Hydrogen and Fuel Cell Technology Innovation Program All the project activities were implemented in Berlin during been taken to pave the way for their implementation and the first phase of the project (2002-2007). The opening of a testing, Nm3 Standard cubic meter public hydrogen fuelling station at the end of 2004 provided • Administrative hurdles in setting up the relevant energy NOW National Organization for Hydrogen and Fuel Cells the public at large – including people from abroad – with an infrastructure and using vehicles with hydrogen have VES Transport Energy Strategy opportunity to catch a glimpse of the forward-looking inno- been identified, vations in fuel and drive systems. More than 3,000 visitors • Great strides have been made in standardizing and certi- from all over the world came to find out more about this fying H2 components and plant and further need for groundbreaking project during its first two-and-a-half years. action has been brought to light, They used the opportunity of asking experts in the various technological fields direct questions.The project, which the Federal Government has made a showpiece for sustainable mobility within the National Sustainability Strategy, quickly developed into a flagship for business and politics and is setting the tone for their ongoing commitment to this process. Last but not least, the Federal Government set up the National Hydrogen and Fuel Cell Technology Innovation Program (NIP) in March 2006 as a result of the visible success of the CEP project.

The project partners, which all play a leading role in technology in the international market, are demonstrating the technical and economic requirements for using hydrogen for road transportation within the CEP. Groundbreaking steps were taken during the first phase of the project to achieve the goals that have been set and important information has been gained to implement them successfully: • Forward-looking hydrogen drive systems and fueling The CEP has been selected as a site in the “Land of Ideas” project in 2007: The CEP is managed by a steering committee Federal Minister of Transport Wolfgang Tiefensee technologies have been successfully demonstrated over the presentation of the prize on 25 May 2007 with Patrick Schnell,TOTAL, of companies involved in the project and the and Dr.Joachim Wolf,Linde,in April 2006 and Thomas Wacker, Deutsche Bank Berlin Federal Ministry of Transport, Building and a period of several years, Urban Affairs

1 The VES is a joint initiative of the Federal Ministry of Transport, Building and Urban Affairs (BMVBS), the energy supply and oil companies Deutsche BP,RWE, Shell, TOTAL and Vattenfall Europe and the vehicle manufacturers BMW Group, Daimler AG, Ford, GM/Opel, MAN and Volkswagen AG. 10 An Overview of the CEP An Overview of the CEP 11

ahead with further developments in hydrogen technolo- introduced the sixth generation of hydrogen cars with its gy for years.The Linde Group operates the only hydrogen Hydrogen7 series vehicle. The BMW Hydrogen7 is the liquefaction plant in Germany.The company supplies the world’s first hydrogen vehicle which has gone through liquid hydrogen for the CEP in fuel trucks. Linde has also the complete series development process and can there- manufactured the dispensers and the compressor equip- fore demonstrate the basic feasibility and everyday avail- ment for the CEP fuelling stations and the steam reformer ability of this technology. for the fuelling station on Heerstrasse. • Daimler AG: Daimler AG is a pioneer in the development • StatoilHydro: StatoilHydro is a fully integrated oil, gas of fuel cell drive systems. Research scientists and engi- and energy corporation. Its involvement in hydrogen neers have been working on the practical implementa- technology goes back to the 1920s. StatoilHydro has now tion of this technology since the early 1990s. Daimler was turned tradition into a modern vision. StatoilHydro is cur- able to present the first “Necar 1”(New Electric Car) with a rently acting as operator and supplier of technologies at fuel cell drive system back in 1994. Other developments several hydrogen fuelling stations. StatoilHydro supplies have followed since then.The F-Cell A-Class is now on the the gaseous hydrogen using electrolysis at the CEP fuelling road, the sixth generation of these vehicles. station on Messedamm in Berlin and, as a result, plays a Federal Minister of Transport Wolfgang Tiefensee at the wheel of a Ford Focus Dominique Perben, French Minister of Transport and Infrastructure, und Wolf- Fuel Cell Vehicle, April 2006 gang Tiefensee, Federal Minister of Transport, Building and Urban Affairs at the crucial role in the sustainable production of hydrogen. • Ford: Ford introduced its first car with a fuel cell drive sys- opening of the TOTAL Station in March 2006, © TOTAL tem in 1998.This was the starting point for ambitious and • Vattenfall Europe: Vattenfall Europe is the third largest intensive research work on hydrogen-powered vehicles. power generating company in Germany and has more The Ford Focus Fuel Cell Vehicle is the latest result of • Valuable knowledge has been gained on the vehicles’abil- ence of the past has shown that these partners are able to than 15 years’ experience in hydrogen energy engineer- these developments. But the Ford engineers are also ity to cope with everyday situations, their level of accept- cope with the remaining challenges in the future and ease ing.So it is in a position to supply the vehicles in the Berlin working on a different technology: Ford believes that the ance with customers, their attractiveness and the refu- the transition to a future with hydrogen as they pull together. demonstration project with clean fuel. Vattenfall Europe hydrogen-powered internal combustion engine is an elling infrastructure and further optimization potential provides energy that has been generated using renew- important intermediate stage along the road towards a has been recognized, The infrastructure partners in this network are: able sources (certified as “green electricity”). future with vehicles running on fuel cells. • It has been possible to increase the general level of • Aral: was the first oil company to begin tests on a fuelling acceptance in the worlds of politics, business, the media, station to supply gaseous hydrogen in 1984.The company • GM/Opel: GM/Opel began development work on fuel cell • Volkswagen AG: Volkswagen has been working on fuel the public arena and with representatives of interested and other partners then developed automatic fueling vehicles at the end of 1997.Some 600 members of staff are cell research for a decade. The “Volkswagen Technology groups and gain positive feedback about the project. robots and now successfully operate a fuelling station for currently working with GM Fuel Cell Activities (FCA) at Center for Fuel Cell and Electric Technology” began its liquid and gaseous hydrogen at Munich Airport.The Berlin five sites in Germany, the USA and Japan on developing research work in Isenbüttel in 2001. About 80 engineers The CEP will continue to consistently pursue the measures fuelling station is another step along the way towards a fuel cell technology to prepare it for series production are developing and testing fuel cell drive systems and that have been started in the first phase in the next phase future with hydrogen.It is one of the first public hydrogen use. electric vehicle components there. The Touran HyMotion from 2008 onwards. The interim results, which have been fuelling stations in the world to be integrated in normal represents the fourth generation of Volkswagen fuel cell obtained during the first few years of operating the plant refuelling operations. • The BMW Group: The BMW Group has been pursuing the cars.The corporation joined the CEP in July 2006. and vehicles, will form the basis for providing solutions to vision of sustainable mobility for more than two decades. unanswered questions about using hydrogen as a fuel.Future • TOTAL Deutschland: TOTAL has been working on hydro- It is developing both conventional technologies and • The Berlin Public Transport Company (BVG) is also taking activities will concentrate on the further optimization of tech- gen applications for transport purposes for years. The hydrogen-powered vehicles as part of the BMW Clean part in the CEP as one of the leading fleet operators in nologies and making preparations for a market launch. practical, customer-friendly use of the new fuel and Energy Project. The BMW Group started carrying out testing hydrogen for public transportation services. The model safety concepts are just as important as the search research into powertrains and vehicles running on hydro- BVG has been operating four buses powered by gaseous for an alternative, environmentally-friendly fuel for the gen as part of this project in 1978. Since that time, huge hydrogen in international combustion engines on regular future.TOTAL set up the second fully integrated hydrogen progress has been made in developing conventional cars – inner-city public services since June 2006.It will operate a 4.3 | The Consortium fuelling station in Berlin on Heerstrasse and operates this but that is not the only thing. The BMW Group has now total of 14 hydrogen buses with internal combustion facility. This fuelling station with its high-tech refuelling The Berlin Clean Energy Partnership has proven that the equipment supplies up to 20 hydrogen buses, the CEP widespread potential of the eleven companies involved and vehicles and the hydrogen buses operated and spon- the consistent joint efforts to resolve issues by the partners sored within the EU’s HyFLEET:CUTE Project.TOTAL joined – which would otherwise be competing with each other – the CEP in July 2005. have been able to release synergies within the project, which have enabled hydrogen to be used as an everyday • Linde: Linde is the world’s largest manufacturer of hydro- fuel now. The companies have taken crucial steps to devel- gen plant and supplies the complete hydrogen value op the technology needed in a very short time. The experi- added chain.The company has deliberately been pushing 12 An Overview of the CEP The CEP in Facts and Figures 13

CEP – A Glance Back 5 | The CEP in Facts and Figures2

The signing of a Memorandum of Understanding (MoU) in May 2002 marked the launch of Europe’s most ambitious project to demonstrate hydrogen production, supply and refuelling technologies and test hydrogen vehi-

2002 cles in customer hands. Hydrogen Cars max. 23 (Ø 17) A consortium agreement established a project partner- with fuel cells max. 19 (Ø 15) ship in October 2003; it has boosted the process of pro- with hydrogen-powered internal combustion engines max. 5 (Ø 2) viding evidence that hydrogen can be used as a fuel that running on GH max. 18 (Ø 14) fits into other systems more than any other initiative 2 running on LH2 max. 6 (Ø 3)

2003 over the past few years. number of customers in the CEP Project 10 The CEP opened the demonstration part of the project number of drivers 180 with a hydrogen fuelling station fully integrated into a Operating data: public Aral fuelling station on Messedamm in Berlin in Federal Minister of Transport Dr. Manfred Stolpe, at the opening of the Aral total mileage covered within the project (estimated) 374,000 km/232,000 miles November 2004. The Aral fuelling station makes liquid fuelling station in November 2004 number of refuelling operations 2,976

2004 and gaseous hydrogen available for refuelling vehicles. amount refueled 12 t TOTAL joined the project as a further infrastructure partner in April 2005. engines running on hydrogen in 2008 as part of the CEP and the European HyFLEET:CUTE Project – and one artic- Hydrogen Buses (Subsidies provided outside the CEP as part of the HyFLEET:CUTE) 4 Test operations at the Aral fuelling station ended in July ulated bus will use a fuel cell hybrid drive system. They with hydrogen-powered internal combustion engines 4 2005. Normal operations began at the fuelling station will provide evidence on a daily basis that hydrogen 2005 running on CGH 4 when vehicles were handed over to customers. could be the fuel of the future for public transit systems. 2 Operating data: The Chancellor’s Office has had an official car powered The Federal Government, represented by the Ministry of total miles covered within the HyFLEET:CUTE project (city traffic) 98,435 km/61,164 miles by hydrogen since August 2005. Transport, Building and Urban Affairs, is not only participat- number of refuelling operations 1,081 ing in this groundbreaking project by providing subsidies amount refueled 22 t The CEP opened a second hydrogen fuelling station in to the tune of € 5 million. The Federal Government is also Berlin-Spandau in March 2006.The hydrogen equipment, playing a significant role in providing a major boost to the which is integrated in a conventional TOTAL fuelling station, Fuelling Stations 2 has been providing liquid and gaseous hydrogen for cars development of forward-looking hydrogen technologies by making the CEP a central element in the National Sustain- integrated in public fuelling stations 2

2006 and buses operated by the Berlin Public Transit System. ability Strategy and by the active involvement of govern- suitable for refuelling cars 2 June 2006:The first two buses in the HyFLEET:CUTE proj- ment representatives on all the major committees within suitable for refuelling buses 1 ect refuelled with hydrogen at the TOTAL fuelling station the project. with LH2 refuelling equipment 2 and started journalist shuttle operations during the 2006 with CGH refuelling equipment 2 FIFA Soccer World Cup as part of FIFA’s Green Goal Initiative. Up to 50% of the following production costs are being sub- 2 local production using electrolysis 1 sidized: Volkswagen AG joined the project as the fifth mobility • Setting up and operating the production and refuelling local production using LPG reforming 1 partner in July 2006. infrastructure at the Messedamm site, Operating data: • Primary costs incurred by the infrastructure partners in- amount of LH supplied 42 t The two hydrogen buses were taken over by the BVG 2 volved in the Messedamm site (auxiliary additional and and put into regular service in August 2006. Two other amount of GH2 produced locally with electrolyser 3.5 t supply systems and project coordination costs), hydrogen buses followed in October 2006 and refuel at amount of GH2 produced locally with LPG reformer 8.7 t • Setting up and operating a joint fuelling station for the the TOTAL fuelling station in Berlin-Spandau. amount of GH produced locally by evaporating LH 16.8 t mobility partners at the Messedamm site, 2 2 All the government ministries involved have been oper- • Improving the BVG bus service station to make it suitable ating hydrogen-powered official cars since January 2007. for H2 facilities, CEP Service Station • Primary costs like project support, safety checks, scientific days in use 222 The LPG reformer began operations in January 2007. support and the Convention Center on Messedamm. number of partners using the service station 5 2007 The test phase for the two fuel cells at the TOTAL fuelling station ended in April 2007.They began normal operations Project Volume to recycle LH2 boil-off. total budget for the first phase of the CEP Project Approx. € 40 million total subsidies for infrastructure (the vehicles in the project are not subsidized) Approx. € 5 million number of partners 11

2 All the data relate to the period after the start of normal operations at the Messedamm fuelling station (1 July 2005 – 1 July 2007). 14 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 15

6 | The CEP 2003-2007: Five Years of Mobility with Hydrogen

6.1.1 | Berlin Messedamm: One of the World’s First Fully Integrated Public Hydrogen Fuelling Stations Starts Business

The following components guarantee that the production and refuelling of hydrogen goes ahead without any problems at the Aral fuelling station on Messedamm: • The electrolyser installed and operated by the project partner StatoilHydro has an output of 60 Nm3/h (2,120 ft3/h), • The compressor manufactured by Linde and operated by Aral, which pre-compresses the gaseous hydrogen in the storage pool and provides the final compression to refuelling pressure of 350 bar (5,080 psi), • The storage units for storing the highly compressed gaseous hydrogen, • The LH2 tank from Linde for storing the very low-temperature liquid hydrogen, • The cryopump for supplying liquid hydrogen from the Europe’s first fully integrated hydrogen fuelling station: storage tank to the vehicles, Opening of the Aral fuelling station in November 2004 with Margareta Wolf, Aral on Messedamm, Berlin • A back-up system for providing gaseous hydrogen from LH , the Parliamentary State Secretary of the Federal Ministry for the Environment, 2 © StatoilHydro 6.1 | Refuelling with Hydrogen • The dispensers for CGH2 and LH2.

Berlin Messedamm, Berlin Heerstrasse – two technological of between 90% and 95% at both sites during the initial phase The fuelling station also has a service station for hydrogen- The conventional part of the integrated fuelling station concepts with a joint goal: The infrastructure partners, of the project, but now guarantees have been provided that powered cars. An H2 information center gives groups of vis- comprises refuelling equipment for gasoline and diesel and Aral/BP, StatoilHydro, Linde, TOTAL and Vattenfall Europe at least one of the fuelling stations will be fully operational at itors the opportunity to discover more about the project an Aral shop with a bistro and a car wash facility. have realized a future dream within the CEP and have inte- any time by coordinating maintenance and service cycles. and the activities of the partners. grated hydrogen refuelling facilities into conventional,commercial gas stations with 24h everyday operations for the very first time. As well as conventional fuels, drivers of H2 Info Info 6.1.1.1 | The Production of Gaseous Hydrogen cars can refuel two kinds of hydrogen at the Aral and TOTAL at the Messedamm Site fuelling stations:highly compressed gaseous hydrogen (CGH2) and liquid hydrogen (LH2). The Fuels Technical Data on the Electrolyser Gaseous hydrogen is produced by electrolysis locally in line with demand using electricity that has been certified as 3 3 Aral officially opened the fuelling station on Messedamm in Price (CGH2/kg) € 8,- at both sites Capacity 60 m /h (2,120 ft /h), being green.The hydrogen that has been produced is then November 2004, and so provided evidence that it was possi- Price (LH2/kg) € 8,- at both sites (corresponds to 5.4 kg/h – subjected to a purification process and this removes any re- ble to combine the latest hydrogen technology with the infra- 12 lbs/h) maining oxygen in the hydrogen.The quality of the hydrogen structure at a conventional fuelling station. TOTAL realized its The fuel prices are specified as € 8/kg (2.2 lbs) of Purity at least 99.99% produced by the electrolyser meets the sensitive demands own concept for the Heerstrasse site by March 2006. This hydrogen at both fuelling stations and this is the Outlet pressure 12 bar (174 psi) of fuel cells. fuelling station not only integrates hydrogen technology in price invoiced to the customers. The comparatively Power consumption max. 310 kW everyday operations at a conventional fuelling station, but high production and supply costs caused by the low Energy consumption The pressure electrolysis technology used on Messedamm 3 its design and operations also take into account the every- level of demand are being subsidized by the Federal for each Nm H2 5.1 kWh was specially developed for the local production of hydrogen 3 day demands of a bus service station.The technologies used Government. The fuels are also exempted from the (per 35.3147 ft of H2) (e.g. at fuelling stations). The HPE 15 (15 bar High Pressure on site to produce gaseous hydrogen may be very different oil tax. The longer-term development of the price Ideal operating temperature 80°C (176°F) Electrolyser [218 psi]) built and operated by StatoilHydro – electrolysis is used on Messedamm and steam reforming depends on the origin of the hydrogen, the level of Max. operating pressure 15 bar (g) (218 psi) makes it possible to produce extremely pure gaseous hydro- at Heerstrasse – but both fuelling stations are committed to demand and the future tax policy on the fuel. Hydrogen from each gen from electricity and water in a highly efficient manner. meeting a joint goal:demonstrating that it is possible to fully l water (0.26 gal) 1 Nm3 (35.3147 ft3) The electrolysis technology that can be used locally makes integrate this technology into tried and tested procedures Noise emissions 78 dB(a) it possible to set up extensive hydrogen infrastructure. One right from the outset. (cooling) 51 dB(a) 5 m away from advantage of the local production of hydrogen using elec- the fan and 48 dB(a) 10 m trolysis is the ability to couple this with demand at the dis- In operating terms, both fuelling stations are closely linked away from the fan penser: The unit only produces the amount of hydrogen to each other. It was possible to guarantee availability levels that is required. 16 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 17

Statement Statement

Bjørn Gregert Halvorsen, StatoilHydro (Norway), the Peter Winkler, Linde (Germany),

Partner Responsible for the Electrolyser System the Partner Responsible for the LH2 System

Field Report on the Electrolyser Field Report on the LH2 System on Messedamm The electrolyser is a key technology element in the CEP During the three years that the LH2 fuelling station has 3 3 project. It clearly demonstrates how hydrogen can be with an output of up to 300 kW (60 Nm H2/h [2,120 ft H2/h]). 6.1.1.2 | The Production and Processing of been operating on Messedamm, the partners involved produced in a sustainable manner at a local site without The idea was to use these units in key areas for demonstra- Liquid Hydrogen have been able to fully meet the demands for reliability, any CO2 emissions.We are more than happy with its per- tion purposes, for example in the CEP.The electrolysis unit safety and everyday operations. Vehicles have been re- formance. We have been able to use our unit for more installed for this project is designed to provide output of 60 Compressed hydrogen is not only produced at the fuelling fueled 1,400 times at this site without any complications. 3 3 than 98% of the time over the past two years. We have Nm /h (2,120 ft /h) and the operating pressure is 15 bar station – centrally produced liquid hydrogen (LH2) is also The plant’s very low tendency to break down should be hardly used the back-up system, which was installed (218 psi). The unit consists of pre-assembled components supplied by fuel truck and stored in a 500 kg storage tank. underlined here – we have had availability totaling additionally, and which can produce gaseous hydrogen and those mounted on a frame, which make it easy to as- 99.99%.The expenditure and effort on looking after and from liquid hydrogen if the electrolyser is not available. semble the unit on site.The unit is also characterized by the Extremely low temperatures (- 253°C/ - 423°F) are needed to backing up the unit have been low as a result. The decision to use a remote control system to manage following: liquefy hydrogen and this requires containers that are insu- the electrolyser was also a good one.We have been able • It requires little space, lated accordingly.The advantage here is that very low-tem- We would say that the integration of the LH2 line at the to guarantee continuous and safe operations without • It has 100% nickel electrodes and a long serviceable life perature liquefied hydrogen has a higher energy density conventional Aral fuelling station has been a complete any problems. And the integration of our technology as a result without the need for any maintenance, per unit of volume than gaseous compressed hydrogen and success as far as reliability is concerned. There has not in the complete system at the fuelling station on • It automatically monitors the gas production, therefore requires less storage area. been a single incident or accident related to safety in the Messedamm has worked well in our opinion. Apart from • It has low operating costs, complete reporting period.Expenditure on maintenance a few initial adjustments to the interface communica- • It has comprehensive online and local safety monitoring Linde uses industrial-scale processes to liquefy hydrogen and servicing work over the whole reporting period has tions related to the compressor system, the technologies systems. where the hydrogen that is being liquefied is gradually cooled also been very low. In conclusion, we can say that the of StatoilHydro and Aral function reliably alongside each using heat exchangers. Liquid nitrogen is the first coolant technology for the LH2 line has fully met targets and the other. The following subsystems are integrated in the hydrogen used in the process. A closed hydrogen cold cycle provides demands placed on it within the CEP project in phase 1. production unit: the electrolysis unit, a transformer with a further cooling, where the cooling power is supplied by ex- As far as future hydrogen infrastructure projects are con- Overall we can say after almost three years of project rectifier, a feed water treatment unit with a storage tank, a pansion turbines. The actual liquefaction of the pre-cooled cerned – or the expansion of the existing hydrogen fuelling experience that the unit has functioned better than we gas purifier, a dryer, gas analysis units, hydrogen detector hydrogen takes place by allowing it to expand by throttling station on Messedamm – particular attention must be had expected. So we would be delighted to be able to systems and a management system. All the subsystems in in a Joule-Thomson valve.Then the liquid hydrogen is stored paid to avoiding what is known as boil-off losses. The continue this successful partnership over the next few the unit are pre-fabricated units and their interfaces are in a tank ready for further use. experience that we have gained through the project years. We would particularly like to optimize the dimen- designed to coordinate with each other.The whole process shows that it makes sense to either use the boil-off gas sions of the unit for the future.A larger storage facility for is controlled by a central process management system. All Linde only uses renewable sources of energy to liquefy the that occurs along the LH2 line by feeding it into the com- gaseous hydrogen in combination with higher amounts the unit parts are housed in a container, which meets the hydrogen produced for the CEP.The fuel has a quality level pressed gas path or use it for energy purposes on site being refueled would make better use of its capacity and ISO standards for containers in its basic design and dimen- of 5.0 when it is supplied and it is therefore suitable for use (e.g. to generate electricity or heat in fuel cells). avoid frequent stops and starts. sions. in fuel cells.

The electrolyser has proved to require little maintenance If necessary, the liquefied hydrogen can be evaporated to and is reliable. It is available for use 98% of the time, so that cover any shortfall on the gaseous side of the plant in air- 95% of the gaseous hydrogen (CGH2) that is refuelled at the heated heat exchangers downstream; for this purpose, it is evaporator works without any outside energy by a process The electrolyser works under pressure, it is compact and Aral fuelling station is produced by electrolysis. heated up to ambient temperature (back-up system). The of heat exchange with the ambient air.The evaporation out- uses less energy than traditional units.The hydrogen is also put is approx. 120 Nm3/h (4,240 ft3/h). Only about 5% of the produced without any pollutants – the only exhaust given The hydrogen center at the Aral fuelling station: on the left, the compression gaseous hydrogen that is produced was produced using off into the atmosphere is oxygen.The production of hydro- unit from Linde, on the right the electrolyser from StatoilHydro Linde filling the LH2 tank at the Aral fuelling station from a fuel truck the back-up system in the first phase of the project. Aral set gen is fully automatic.The electrolyser in Berlin is managed up this facility to guarantee supplies. This unit has been from a central control point in the Norwegian town of Rjukan; largely redundant during the course of the project due to this is to test whether it is possible to set up extensive local the high degree of reliability of the plant and the ability to hydrogen production facilities. work in tandem with the TOTAL fuelling station.

Vattenfall Europe ensures with green certificates that the equivalent of the energy required to operate the electrolyser is produced from recently installed renewable energy 6.1.1.3 | The Compression and Storage of plants and is fed into the grid at almost the same time.This Gaseous Hydrogen prevents CO2 emissions and significantly eases the problems for the environment caused when fuels have to be The pure hydrogen gas, which comes from the electrolyser, transported. is dried and stored for a while in a pressurized vessel at a filling pressure of 8 bar (116 psi). This supplies the high-pres- The state of developments at the start of the project in 2003 sure compressor downstream with constant intake pressure. meant that it was possible to manufacture individual units A two-stage compressor is used to compress the hydrogen – 18 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 19

Info

The Compressor Station

Dimensions L x W x H 5.0 x 2.6 x 2.9 m (16.4 x 8.5 x 9.5 ft) Weight 28 t this operates using a high booster process.The hydrogen is Electrical connection 400 V – 50 Hz – 45 KW compressed from its intake pressure to a level of 300 bar Flow rate in normal mode 150 Nm3/h (5,300 ft3), (4,350 psi). This occurs in two stages: The pressure ratio at at 15 bar (218 psi) intake- the various stages is dictated by the incoming pressure pressure level. The compressor uses electricity very efficiently and Flow rate in booster mode 2,580 Nm3/h (91,100 ft3) makes the fueling of vehicles its top priority. The design Specific drive performance 0.165 KWh/Nm3 system ensures storage banks are only filled with the hydro- (35.3147 ft3), related to 15 gen produced by the electrolyser when refuelling is not bar (218 psi) intake pressure going on. Intake pressure min. 5 bar (73 psi), max. 300 bar (4,350 psi) The two compressor stages are driven hydraulically and are H2 connection 1“ SAE also cooled with hydraulic oil in the outer shell.This produces Ambient conditions Unit is built to be set up in what is almost isothermal compression.The unit works with- the open air out needing any oil on the gas side.The hydraulic drive sys- Noise level 65 dB(A) tem is separated from the parts in direct contact with the Approval body TÜV H2.A monitoring system switches the compressor off imme- Working process 2-stage 4-cylinder HB unit diately if a breakdown occurs. with almost isothermal compression The hydrogen is stored for a while in two buffer sections Filling pressure 300 bar (4,350 psi) The LH2 area at the Aral fuelling station with LH2 tank, LOPEX system, GH2 refuelling, © StatoilHydro (banks).The compressor’s performance during normal oper- Final compression pressure 450 bar (6,530 psi) cryopump and evaporator ations is about 150 Nm3/h (5,300 ft3) if the intake pressure is Max. fueling pressure 428 bar (6,210 psi) 15 bar (218 psi).This requires 23 kW of electrical power.The low-pressure bank and the medium-pressure bank are both The hydraulic unit and the complete electrical installations instruments for automatic operations like a manometer and filled with H2 at 300 bar (4,350 psi) when the unit is ready to are housed in the electrical room. The drive system for the filling level. The contents and pressure in the tank are also operate. The high-pressure bank is simply a 50 l (13.2 gal) compressor stages is provided with the help of hydraulic oil remotely monitored by the Linde center that is responsible buffer and can be filled with gas at 450 bar (6,530 psi) or 850 Info in the part of the housing that is explosion-proof (gas room). for the unit. bar (12,330 psi). All the pipes are designed to be gas-proof. All the fixtures in

The CGH2 Buffer Store the gas room are designed according to explosion zone 1 Alongside the above mentioned evaporators, there is a liq- If a vehicle is waiting to be refueled, the initial pressure in specifications.A pressure relief valve is housed in the roof of uid hydrogen transfer pump with an output of 3,000 l/h the vehicle tank is checked by a test surge. This produces a LP bank 2 clusters with 2x50 l (13.2 gal) the gas room. All the technical gas equipment is housed in (792 gal/h) arranged downstream; this transfers the LH2 temperature rise graph and this is compared with the out- bottles or depending on the the gas room.The air in the room is monitored to check that through vacuum-insulated hoses to the LH2 fuel nozzle. side temperature.This provides the filling pressure required. design no hydrogen is escaping; if this happens, the compressor The test surge is fed from the high-pressure buffer. As the MP bank 2 cluster with 2x50 l (13.2 gal) station is switched off and the individual sections are iso- pressure falls in the high-pressure buffer, the compressor is bottles or depending on the lated using fast closing pneumatic valves. The instrument switched to booster mode.The refuelling process then starts design air compressor is located in the unit’s electrical room. The 6.1.1.5 | Hydrogen Refuelling from the low-pressure bank. Then the medium-pressure HP bank 50 l (13.2 gal) unit has its own breakdown matrix which ensures that it 3 3 bank is equalized.The filling process to final pressure is cov- Total gas volume 1,944 Nm (68,650 ft ) or always operates in a safe state. A vehicle can be refueled using an LH2 or a GH2 dispenser. ered by the booster mode. The booster takes gas from the depending on the design They are positioned centrally next to each other on the fuelling medium-pressure bank and compresses it to max. 450 bar LP storage pressure 300 bar (4,350 psi) station forecourt. When a vehicle is being refueled with (6,530 psi) in the first stage and,if needed,to 850 bar (12,330 MP storage pressure 300 bar (4,350 psi) hydrogen, the dispenser and tank neck are connected to- psi) in two stages.The intake pressure is at least 50 bar (725 HP storage pressure 450 bar (6,580 psi) 6.1.1.4 | Storing the Liquid Hydrogen gether by special couplers.Various systems are used depend- psi). Approx. 40 kW of electrical power are needed during Filling medium Hydrogen ing on which type of hydrogen is available.The connections booster operations. LP testing pressure 495 bar (7,180 psi) Liquid, low-temperature hydrogen is of a very high quality are pressure-tight, fully insulated and gas-proof. A liquid MP testing pressure 495 bar (7,180 psi) and does not require any further processing on site.The liq- pump, what is known as a cryopump, is used for low-tem- The filling capacity in booster mode at 450 bar (6,530 psi) is HP testing pressure 675 bar (9,790 psi) uid is stored in a tank designed as a double-shell container. perature liquid hydrogen in a manner similar to when refu- 15 Nm3/min (530 ft3/min) to 20 Nm3/min (707 lb3/min). The The inner container, which holds the very low-temperature, elling with conventional fuels; but when refuelling with gas that is drawn in from the medium-pressure storage facil- liquefied hydrogen (- 253°C/- 423°F), consists of Cr-Ni steel gaseous hydrogen at 350 bar (5,080 psi), the process takes ity is supercooled because of the previous refuelling process that remains tough at subzero temperatures and the outer place using a compressor. (at approx. - 40°C/- 40°F) and so the booster output temper- container is made of structural steel. The cavity is filled with ature is 10°C (50°F) on average. It takes about 120 seconds The complete compressor unit is housed in a concrete con- fire-proof insulation material (perlite) and the air is also The dispenser at the two CEP sites on Messedamm and to fuel a car with 25 Nm3 (880 ft3). tainer which consists of an electrical area and a gas area. drawn out. The tank is equipped with all the necessary Heerstrasse were supplied by Linde. They provide maxi- 20 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 21

Statement

• Guarantees a defined flow volume resulting from a defined difference in pressure between the LH2 storage tank Detlef Dietrich, and vehicle tank through an LH2 transfer pump, Fuelling Station Leaseholder • Minimizes the H2 gas phase that occurs during the refu- of the Integrated Aral Fuelling elling process by supercooling the LH2 using an LH2 pump. Station on Messedamm

Field Report on the Fuelling Station Operations

6.1.1.6 | Electricity Supply Since the fuelling station was opened in 2004, my twelve members of staff and I have been looking after the inte- Only renewable electricity is used to operate the plant grated Aral fuelling station on Messedamm around the on Messedamm (including the electrolysis equipment) in clock. The CEP vehicles are mainly refueled during the order to prevent CO2 emissions that would relativize the daytime, between 7 a.m. and 8 p.m.This is because most success of the project. The electricity, which is produced of the drivers are only using the vehicles for business using renewable energy sources, is supplied by Vattenfall purposes. But sometimes these vehicles are refueled at Europe AG.Vattenfall Europe AG supplies approx. 120 – 150 night. Normally the refuelling procedures fit in well with Info LH and GH dispensers at the Aral fuelling station 2 2 MWh of electricity from renewable energy sources every our “normal” fuelling station operations.

The CGH2 Dispenser year using certificates as part of the project. Because the fuelling station operates semi-automatically, Throughput meter Turbine throughput measure- The dispenser for refuelling vehicles with gaseous hydrogen The certificates that are issued are part of the “Renewable my main job with regard to the hydrogen technology is ment with mass analysis has a filling connector supplied by WEH (model TK 16) and Energy Certificates System” (RECS). They are proof of origin to carry out a visual check of the unit every day and occa- Throughput rate Max. 90 g/sec (3.17 oz/sec) it is designed to handle refuelling pressure of no more than documents and provide information about the origin, type sionally activate it, if one of the equipment areas needs Pressure stage 350 bar (5,080 psi) 350 bar (5,080 psi). The turbine flow meter measures the of generation, size of the power station and the time at to be reset. Minor disruptions, which do occur at times, Electrical connection 230 volt / 50 Hz amount of fuel passing through. The maximum throughput which the power was fed into the grid.In this way they meet are usually dealt with by the partners by remote control. Housing design High style made of stainless is approx. 40 m3/min (1,410 ft3/min). The fully automatic the demands made by the European Commission to mark We all enjoy working at this forward-looking fuelling sta- steel refuelling procedure is completed when the filling pressure electricity from renewable sources.The certificates are issued tion very much and my colleagues and I are filled with a Display 6-figure (DM = 4+2 comma / calculated by the temperature compensation unit has been by what is known as an “Issuing Body”; in Germany this is certain sense of pride that we can participate in the CEP Euro = 3+3 comma) reached in the vehicle’s tank. the Öko-Institut e.V. This organization issues the electricity project.In my opinion, it is important to develop and test Process controls Siemens SPS providers with the RECS certificates for each MWh of elec- technologies to use environmentally-friendly fuels in order Drain valves Pneumatic seat valves The refueled amount is transmitted by the dispenser to the tricity.The certificates are deposited in the accounts of plant to pass on to our children a world that is worth living in. Temperature compensation Via Siemens SPS Program fuelling station management system (TMS). The amount This compensates for the small amount of additional Interface Tokheim WWC-LON refueled (in kg) and the final price (in €) are displayed on the work that is involved. But in general I can confirm that Retraction coupling For hose and breather electronic display head and an invoice is sent to the customer. the technology is already able to cope with everyday sit- Hoses Refuelling and breather, The hydrogen centre at the Aral fuelling station: on the left, the compression uations,at least with the number of refuelling operations station from Linde, on the right the electrolyser from StatoilHydro, in the each 4 m (13.1 ft) long A separate dispenser is used to refuel vehicles with liquid middle the buffer section that we handle at the moment. EMERGENCY OFF switch On the front of the housing hydrogen. The liquid hydrogen taken from the LH2 storage Refuelling coupling WEH TK 16 tank and fed through the liquid transfer pump passes through The level of interest from “normal” customers in the the fuel nozzle and coupling between the vehicle and dis- hydrogen activities that we are demonstrating here on penser. Messedamm is still low.We wish that we were more popular and this could certainly be achieved if the activities The LH2 dispenser on Messedamm has the following func- here at the fuelling station were promoted more in the tions: public arena. • Manual connection of the cold-drawn coupling at the mum safety and a relatively high degree of user comfort. refuelling neck of the vehicle, As for the future, I hope that the excellent level of coop- The dispenser for liquid hydrogen at the Heerstrasse site is • Automatic leak test on the connected coupling using heli- eration with the partners will continue and that the inte- very special. A newly developed, second generation tank um pressure monitoring, gration of H2 fueling procedures and LH2 supplies will be coupling is in service here. It was optimized in line with the • Automatic, pneumatic positioning of the cold finger of further optimized within the normal framework of experience of CEP test customers – and it marks a further the coupling on the gas-proof connection of the refuelling fuelling station operations. Using this fuel should step towards a future with hydrogen. The Messedamm site hose and vehicle, become commonplace in the future and no longer be will also be equipped with this new coupling in the coming • Automatic cold flow process for pipes and refuelling pipe significant because it is the exception. phase of the project. at the start of the refuelling procedure, 22 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 23

15432 1600

LH (#) 2 1400 13227 LH2 (lbs) GH2 (#) GH2 (lbs) 1200 11023

1000 (lbs)

2 8818 800 operators and are then transferred on to traders or final cus- Personnel were given instruction and all those involved 6613 tomers or consumers.When the origin is finally used to prove were also trained during this period. As the test phase did 600 amount refueled H amount refueled 4409 that the energy is electricity from renewable energy sources not reflect everyday operations at the fuelling station, oper- 400 number of refueling operations (green electricity), the certificates are validated. ating data were not collected in a structured and complete 2204 manner until the key date of 1 July 2005.The analyses listed 200

Vattenfall Europe also sets its own requirements for the below therefore relate to the 24-month period of everyday 0 0 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 “quality” of the certificates. All the certificates for the CEP operations on Messedamm between July 2005 and July /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 0 come from new power plants (commissioned since 1998) and 2007. 0 0 0 1 1 1 0 0 0 0 0 0 0 0 0 1 1 1 0 0 0 0 0 the electricity is fed into the grid at almost the same time as Figure 1: Refuelling amounts and frequencies at Messedamm Detlef Dietrich, leaseholder at the Aral fuelling station, during his daily visual the certificates are issued. An equivalent of the energy used check of the hydrogen equipment, here in the LH2 area, © Dietmar Gust Foto- on Messedamm has been produced by a Swiss hydroelectric grafie, Berlin power station and an Irish offshore wind farm. In this way 6.1.1.8 | Maximum Operation Tests Vattenfall Europe ensures that the CEP vehicles are actually being supplied with clean fuel from the source to the The CEP organized two weeks of maximum operations in During the one-week tests on the LH2 and GH2 side of the The comparison of the figures allowed the experts to spec- wheel. the fall of 2006 where all the available vehicles and drivers fuelling station, the operating data at the station, which ify in more detail the supposed shortfalls of hydrogen dis- were mobilized to use a fuelling station as often as possible were gathered in aggregate form each month, were broken covered in the run-up to the tests and examine the reasons and refuel large amounts of hydrogen.The Aral fuelling sta- down into time periods. It was possible to analyze in detail for them. tion on Messedamm was selected to serve as a showcase and evaluate the interaction of the various parts of the sys- 6.1.1.7 | The Results ... – Three Years of Opera- for this series of tests.The aim of the maximum operation test tem locally as a result of this data in combination with the The most important results of the maximum operation test ting Equipment on Messedamm weeks was to simulate full utilization of the fuelling station information collected by the drivers each time that they weeks were: to prove that it could cope with future everyday conditions. refueled (change in tank pressure, tank volume, time taken • The capacities of individual plant areas were not complete- Test operations initially took place at the hydrogen fuelling The results of the maximum operation tests enabled the to refuel, any error messages etc). ly utilized – e.g. the electrolyser was only used for 40% of station on Messedamm from November 2004 until June 2005. experts to identify weak points in the system engineering its total productive capacity. During production times the The equipment parts were coordinated during this period or plant equipment. This had not become evident in previ- electrolyser was operating at 84% of its peak perform- and optimized to ensure that they functioned well in tan- ous operations on account of the low demand in relation to ance and on average produced 4.6 kg (10.1 lbs) of H /h. LH2 GH2 2 dem. Vehicles were made available to the first customers. the supply capacity. • The dimensions of the GH storage facilities are too small Number of vehicles in use 4 13 (+3) 2 to handle constant demand. This is primarily due to the Number of refuelling operations 51 147 system design of the unit,as GH2-fueling requires the high- carried out booster operations from the compressor which is then 300 kg 184 kg during this time not available to fill up the storage tanks GH Amounts refueled 2 Total (660 lbs) (405 ls) at the fuelling station. Production amount 3,513 kg (7744 lbs) Breakdowns/problems 2 6-7 • It was not possible to reduce the shortfalls in amounts of Production time 806 h hydrogen on the GH2 side in comparison with the previ- Table 1:The CEP maximum operations test weeks (September and October 2006) ous month. But the shortfalls on the LH2 side were Number of starts/stop on the electrolyser 97 (since January 2006) reduced by utilizing the plant to a greater degree. Average utilization of the electrolyser 5% • It was possible to significantly increase the energy effi- Lowest amount produced in a month 67 kg (147 lbs) The following output data were gathered in the test week ciency of the H2 production process by the larger amounts and were compared with the data from the preceding of fuel that were refuelled and because the electrolyser Largest amount produced in a month 361 kg (794 lbs) months: was subjected to starts and stops less often (15% lower ener- Average amount produced per month 146 kg (321 lbs) • The numbers of refuelling operations and the times at gy consumption per amount of GH2 that was produced). Electricity consumption 236 MWh which this took place for specific vehicles, • The number of error messages in the system was reduced. • Refuelling times, Water consumption 30,348 l (8,018 gal) • Amount of produced and refuelled hydrogen, In particular the knowledge gained about the differences LH2 Total • Number and amounts of LH2 deliveries, between the hydrogen that was made available and actually Amount supplied 18,311 kg (40,284 lbs) • Error messages, refuelled (which were booked as “shortfalls” in the past) • Energy consumption, made the maximum operations test a major success and Number of deliveries 39 • Availability of the plant, improved some other test measurements and the data col- Smallest amount supplied 235 kg (517 lbs) • Noise emissions from the electrolyser and compressor. lection and analysis processes within the project. The origi- Largest amount supplied 582 kg (1,280 lbs) Average amount supplied 470 kg (1,034 lbs) 3 In the run-up to the maximum operation test weeks, shortfalls meant that there was a difference between the amount of hydrogen made available and refuelled into vehicles at the beginning and end of any month taking into consideration the differing tank capacities. 24 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 25

throughput measurements and using the Coriolis principle. There are three locations at the Aral fuelling station where hydrogen is “measured” in different ways: on the electrolyser using an ammeter (measuring the flow of electrons),on the dispenser using a throughput meter and in the vehicle using its sensors.

The partnership is of one mind with regard to the results of the maximum operation test weeks: It was possible to obtain valuable knowledge, which had not been available in this form, from this first major test and this information will be included in the subsequent work performed by the consortium. Major fields of action for future project phases have already been defined by tapping into valuable potential for future plant and process optimization.

Opening of the CEP TOTAL fuelling station on Heerstrasse in March 2006 with port and Infrastructure Dominique Perben and Thierry Pflimlin, CEO at TOTAL TOTAL fuelling station with the new LH2 coupling, © TOTAL Federal Transport Minister Wolfgang Tiefensee, the French Minister for Trans- Deutschland GmbH, photo on the left: © TOTAL 6.1.2 | Berlin Heerstrasse: Energy-Optimized Refuelling nal belief that shortfalls were actually losses within the or supply it to the vehicles from the storage tank, the elec- as is the case on Messedamm.The TOTAL station was realised plant was far too imprecise on closer consideration. The trolyser has to release hydrogen into the atmosphere if The TOTAL hydrogen fuelling station in the Spandau district with a spatial separation of the conventional and the hydro- shortfalls can now be attributed to four reasons: refuelling operations are taking place at the same time. As of the city is the second CEP site in Berlin. It was opened gen refuelling sections due to the combination of the dis- • Operating needs, the refuelling operations are of a short duration (three – five with a celebration in March 2006 as the first public hydrogen pensers for hydrogen passenger cars with the dispensers • The H2 needed for repair/maintenance purposes, minutes), it does not make operating sense to halt the elec- fuelling station operated by TOTAL in Berlin. The hydrogen for hydrogen busses on the BVG bus depot side. • Imprecise measurements, trolyser’s production capability. This correlation was recog- technology has been completely integrated in the conven- • And finally real losses which account for the lowest pro- nized during the maximum operation tests in October 2006 tional fuelling station operations here too. portion of the figures. as the production times on the electrolyser often coincided with the times that the vehicles were refueled. This type of In contrast to the fuelling station on Messedamm,an operator 6.1.2.1 | Producing and Processing Gaseous The first two categories do not represent any losses from operating need can, however, be classified as low for everyday model was selected here which only has one owner for all Hydrogen at the Heerstrasse Site the system, but extraordinarily high operating needs for H2 operations at a fuelling station, as the production and refu- the parts of the plant: TOTAL Deutschland GmbH. From an may point to real losses. The analysis and quantification of elling times rarely correlate closely.A larger storage container organizational point of view,this operator model has proved The gaseous hydrogen supplied at the fuelling station can the arithmetical uncertainties and reducing them is one of could further ease the problem as the production times for the to be superior to the one used at the Messedamm site.There be produced or generated at the site in two different ways: the major tasks in the next CEP phases. electrolyser could largely be moved to the night time. each of the three infrastructure partners (Linde, StatoilHydro Through LPG steam reforming and evaporating LH2. and BP) operate the parts of the plant that they have installed. Operating needs: The operations at the plant require a cer- An increase in the need for H2 for operating purposes was An operator agreement governs the interaction of all the A steam reformer of type CT-H2 3/0050 supplied by Linde tain amount of H2 to be used as working materials for safe- discovered in the first half of 2006. Gaskets were replaced components and responsibilities. has been producing gaseous hydrogen by means of ther- ty reasons – e.g.to prepare (rinse) the pipes.Varied amounts during maintenance work and the original state was restored mal splitting from LPG (Liquefied Petroleum Gas or propane of H2 are required for each amount produced depending on as a result. The aim of the system design at the TOTAL fuelling station is gas) since January 2007.The gas used here is pure propane the frequency that demands are placed on the plant (more not only to demonstrate that car and bus refuelling equipment gas. The reformer has a production capacity of 100m3/h 3 frequent starts of the electrolyser and the compressor mean Amounts of H2 for maintenance/repair work: H2 is need- can be successfully integrated in a conventional fuelling (3530 lb /h). more need for H2 than a few longer production cycles, even ed for rinsing purposes during all kinds of maintenance and station, but also to optimize the energy flows in the complete though the amount produced may be the same). The sys- repair work.The amount consumed is governed by the type system. This is primarily achieved by making full use of the The propane gas is divided into two flows – the flow of tem design also has a major influence on the amount need- of activity and the system design (length of the pipes need- boil-off from the liquid hydrogen storage facility in two sta- combustion gas and fission gas – at the inlet point on the ed as a working material: If the compressor and electrolyser ing to be rinsed). tionary fuel cells. In this way it is possible to reduce the loss- plant.The latter is fed to the reformer for propane gas steam communicate with each other in a less than perfect manner es from boil-off to almost zero. reforming, while the flow of combustion gas is used to heat or if the H2 cannot be supplied to the compressor at the Imprecise measurements: Measuring amounts of hydro- the reformer pipes. same time, the hydrogen produced by the electrolyser will gen is a challenging task from a technical point of view and Hydrogen is also supplied at four different dispensers at this be released into the atmosphere for safety reasons. The has not yet been completely mastered. Amounts of hydro- fuelling station in liquid form and as compressed gas for Before hydrogenation and desulfurization, the fission gas is design of the system is like this at the Aral fuelling station: As gen are currently measured using the following measuring refuelling at 350 bar (5.080 psi) for cars and buses.The liquid compressed to approx. 17 bar (246 psi) in a single-stage pis- the compressor can either accept H2 from the electrolyser processes: measuring the difference in pressure, turbine hydrogen is supplied by the project partner Linde by truck, ton compressor. 26 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 27

oxide.The LPG leaves the desulfurization stage with a sulfur ide on an iron/chrome catalyst at approx. 310°C/590°F.This Statement content of less than 0.1 ppm and it is cooled down to reaction is exothermic,so this gives rise to a reactor temper- approx. 230°C/ 446°F before it enters the reformer. ature of approx. 400°C/752°F at the outlet point: Patrick Schnell, will be possible to operate the fuelling station without TOTAL Deutschland GmbH, any losses from the LH tank once the next two buses The drinking water used is fully desalinated before it enters 2 CO + H O CO + H Manager Responsible for have been delivered. But in contrast to the excellent the steam reformer in a multi-stage process, consisting of 2 2 2 the Heerstrasse Fuelling performance of the LH2 part, the local production of softening, reverse osmosis and ion exchange. The desali- Station in Berlin hydrogen from LPG using a reformer has turned out to nated water evaporates in the reformer and is split togeth- As a result of the subsequent cooling of the reformate in the be difficult and cost-intensive from a technical and opera- er with the propane gas at a process temperature of approx. shell-and-tube heat exchanger, the majority of the steam We believe that the CEP – tional point of view. Current knowledge suggests that it 850°C/1,562°F into a hydrogen-rich synthesis gas, the refor- that remains in the reformate is condensed, removed and and we operate our hydrogen will be very complicated to reduce the cost of this process. mate. This consists of hydrogen, carbon monoxide, carbon fed to an outlet point via a degasifier. After the water has fuelling station on Heerstrasse dioxide, methane and steam. The heat energy required for been removed, the reformate is purified in the pressure within this scheme – is an exceptionally successful proj- Despite some unforeseen problems, overall the opera- this process is supplied by a gas burner.Propane gas is used swing adsorption (PSA) unit and is split into hydrogen gas ect. The level of cooperation with the Berlin Senate tions at the fuelling station can be described as positive. as the combustion fuel for start-up operations. The waste and residual gas.The hydrogen is subjected to a purification Department of Urban Development and the Senate Although we did not assume that operations would gas from the PSA unit, what is known as residual gas, is used process and it then has a level of purity which allows it to be Department of Economics, Technology and Women’s proceed without any breakdowns, the system has later during normal operations. This provides approx. 90% used in fuel cells.The hydrogen that is produced is continu- Affairs in constructing the fuelling station was very con- required a higher level of personnel support than we of the heat requirements, so only a small amount of ally monitored by an analysis unit to check the level of any structive.Important knowledge about the interaction of had expected. This has been caused by various techni- propane gas has to be added. A lambda sensor in the waste carbon monoxide impurities.The analysis and calibration of the plant components would not have been possible cal problems, the time-consuming insertion or conver- gas pipe from the burner checks that the combustion gas the measuring tool take place automatically. without the exceptional planning permission granted sion of plant components and adjustment problems at has been completely burned with excess air. by the Berlin Government to produce hydrogen locally the start of operations. It has been possible to reduce The cooling water required for the process is supplied using the LPG reformer. The level of cooperation with what were high noise levels for the residents in the The temperature of the gas is regulated and it is then fed to through a closed heat rejection system which is located on the Berlin State Office for Health and Safety at Work, immediate vicinity of Heerstrasse caused by the com- what is known as the CO shift stage. The carbon monoxide the roof of the unit container. During particular operating Health Protection and Technical Safety (LAGetSi) and pressor operating at night by adopting two noise and steam start to convert into hydrogen and carbon diox- phases, the unit requires nitrogen which is supplied from the certified monitoring office that was selected (TÜV reduction measures. An official survey and feedback Rheinland Industrie Service GmbH) has been excellent. from local residents are evidence that the legal specifi- Professional and committed members of staff at both cations are now being adhered to any time of the day or institutions have supported us in all the issues ranging night. from gaining building permission to operating the fuelling station.We also involved the Berlin Fire Depart- We are expecting a significant increase in the number ment in the project at an early stage and we regularly of vehicles in the future, both cars and buses. TOTAL is receive visits from interested fire department groups therefore planning another fuelling station with refu- that wish to discover more about hydrogen technology elling facilities for 50 buses in Berlin. Our attention and at our site. that of our partners will focus on further technical developments to the components in order to optimize the We are particularly proud of the way that our LH2 units everyday availability of the compressors, measuring work: The plant operates without any breakdowns and equipment, hoses and dispenser in particular. It goes it has been possible to considerably reduce the boil-off without saying that we will convert tank equipment to from the tank by operating the fuel cells and the grow- 700 bar (10,150 psi) and test this forward-looking tech- ing demand for GH2 from the buses. We assume that it nology too.

After the compression process,the LPG is heated in two stages perature for the subsequent hydrogenation stage. During to 320°C/608°F. In the first stage the gas is heated up in a the hydrogenation stage, the sulfur in the LPG is converted recuperator – this heats up the gas mixture to approx. with the hydrogen into hydrogen sulfide on a cobalt/ 250°C/482°F in a counter current flow to the desulfurized molybdenium catalyst. Any unsaturated hydrocarbons and LPG. The ongoing temperature increase is provided by an possible oxygen is hydrogenated. In the subsequent desul- electrical heater which is used to regulate the intake tem- furization stage, the hydrogen sulfide is adsorbed with zinc Figure 2: Process cycle for H2 production in the steam reformer, © TOTAL 28 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 29

two nitrogen packs at an automatic supply station. All the 44092 GH2 (buses, BVG compound) 40 589 GH (buses, BVG compound) 2 LH (car) flows of waste gases, which normally only accrue in start-up A special automotive coupling is used to connect the dis- 39683 2 LH2 (car) GH2 (car) and stopping operations or when the unit is switched off in penser to the vehicle; the coupling is thermally sealed from 35273 GH2 (car) an emergency, are collected in a common pipe. A bi-direc- the atmosphere even if the flow of low-temperature hydro- 30864 tional detonation safety device has to be passed before the gen lasts for some time.Otherwise the moisture in the atmo- 26455 gas is transferred for cold discharge. sphere would condense and this would mean that refuelling 22046 17636

operations for other vehicles would only be possible after (lbs) amount refueled 14 475 All 14 buses that are used as part of the HyFLEET:CUTE Proj- 1 2 the ice that had formed on the coupling had melted (the 13227 ect are refueled at the TOTAL fuelling station. Six buses are leakproofness of the coupling connection is essential to 8818 4023 3701 4409 currently being used for everyday operations (see chapter ensure proper refuelling operations).The unit checks whether 489 522 0 7.2.10). As soon as the fleet has been expanded to seven the system is leak-proof using helium and interrupts the 2006 2007 vehicles, the capacity of the steam reformer will no longer Figure 3: Couplings for LH2 fueling process if any problems should occur. 1 The former manual version 2 The latest automotive coupling Figure 3: Refuelling amounts at Heerstrasse be adequate to supply the hydrogen that is needed and a two-pronged supply strategy will be required: In this case The LH2 fuel pump installed at the TOTAL hydrogen fuelling GH Total additional GH2 will be supplied by evaporating LH2 – as is station still had the older type of cold-drawn coupling in the 2 the case if the reformer is not available on account of main- public area of the fuelling station until September 2006 – 5,457 kg amount produced tenance or a breakdown.The plant controls are designed in this is still the type used at the Messedamm site. Based on (12,005 lbs) such a way that boil-off gases from the LH2 tank are prefer- the experience gained with the cold-drawn coupling and running time 3,389 h ably fed to the precompressor prior to the hydrogen from particularly because of its ergonomic disadvantages, Linde availability 94% the steam reformer if the steam reformer still allows a pressed ahead with the development of a new generation reduction in output (up to 25%). of coupling.The weak points of the refuelling process, which lowest amount produced in a month 233 kg (512 lbs) become obvious at the interfaces with customers, called for largest amount produced in a month 1,450 kg (3,190 lbs) An air-heated evaporator is used to supply the fuel;this evap- the immediate development and rapid deployment of tech- average amount produced per month 909 kg (2,000 lbs) orator converts the liquid hydrogen, which is stored in an nical solutions, as both the vehicles and fueling units have 38.564 Nm3 LH tank at 2 bar (29 psi), to the gas phase. The pressure of to have fitting coupling parts and any retrospect conversion LPG consumption 2 (1,361,8765 ft3) the evaporated hydrogen is then increased to approx. 25 of fairly large vehicle fleets is a complicated and expensive electricity consumption 77.3 MWh bar (362 psi) using a screw compressor and the fuel is then undertaking. As a result, the old type of LH2 coupling has fed on to the main compressor (high-booster compressor). only still been in use at the BVG depot since September water consumption 396 m3 (13,984 ft3)

2006. The LH2 fuel pump on the public side of the fuelling LH2 Total There are clear advantages in using a precompressor: On station has the new LH2 automotive coupling, which can 24,876 kg amount supplied the one hand, the pressure of the liquid hydrogen does not also be used for refuelling LH2 buses in the future. (54,727 lbs) have to be increased using a liquid pump to ensure that it 19,870 kg reaches the minimum inlet pressure on the main compres- Refuelling buses at the TOTAL fuelling station, © TOTAL LH availability for GH refuelling 2 2 (43,714 lbs) GH sor for safety reasons. On the other hand, the compression 2 performance of the main compressor is raised if the pres- 6.1.2.3 | The Results ... – Plant Operations at boil-off amount in the fuel cells* 233 kg (512 lbs) sure of the inflow is higher. 6.1.2.2 | Supplying the Liquid Hydrogen on Heerstrasse after 15 Months Table 2 and 3: Performance and operating data for the LPG reformer (Jan. 2007 - Heerstrasse June 2007) and for the LH2 sector (March 2006 until June 2007) This technology satisfies the requirements for fueling buses, The LPG reformer has been operating since January 2007. (*) The fuel cells were not commission until April 2007, so the figures are still relatively small. for it creates an opportunity to refuel several buses one after The liquid hydrogen is supplied by truck and is kept ready for Refuelling with gaseous hydrogen was covered by evaporat- the other. The refuelling pressure at this fuelling station is use in a cryotank containing 17,600 l (4,650 gal) at a pressure ing LH2 in 2006. The data relate to the periods in question 350 bar (5080 psi). level of 2 bar (29 psi) and a storage temperature of -253°C/ from the time that parts of the equipment were commis- 423°F in a manner similar to the liquid hydrogen equipment sioned until 1 July 2007. the pipe systems if the substance is stored for a considerable But the technology that has been installed will quickly at the Aral fuelling station on Messedamm.A cryopump is used period or if refuelling frequencies are low.Various procedures reach its limits if the size of the bus fleets increases. As a to feed the liquid hydrogen.In order to keep losses in the feeder are possible for handling the gaseous hydrogen that is formed: result, an ionic compressor was installed in October/No- pipes to a minimum,they were designed as short as possible. • The CEP in principle opposes any atmospheric release vember 2007 as part of the EU’s HyFLEET:CUTE Project. The 6.1.3 | LH2 Boil-Off of unused gaseous hydrogen as this represents a real ionic compressor operates like a piston compressor, but Liquid hydrogen is currently refuelled into two BMWs with an loss of energy which contradicts the central principles of uses an ionic liquid to separate the hydraulic fluid and internal combustion engine and one Opel HydroGen3 with a Because of the very low temperatures required to store LH2, the partnership. hydrogen instead of pistons. This means a far lower friction fuel cell during normal CEP operations.The GH2 refuelling oper- it is impossible to completely prevent heat input into the LH2 • Compressing the gaseous hydrogen that occurs and loss in the compressor and therefore a significant increase ations for cars largely take place at the Messedamm site and infrastructure despite elaborate insulation measures. This feeding it to the CGH2 fuelling facilities makes sense in in performance. the fuelling station on Heerstrasse serves as a back-up facility. can lead to evaporation in the cryotank, the cryopump and principle if the demand for CGH2 is expected to be suffi- 30 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 31

Info

The LOPEX Reliquefaction System

Tank Tank pressure 3.5 bar absolute (51 psi) Boil-off amount 140 Nm3/day ciently high.The current low demand for the fuel is hinder- (4,944 ft3/day) process. The amount of gas required is extracted from the ing any extensive tests on the GH2 production facilities at Heat exchanger tank. The extraction process takes place in the same condi- the sites. Insulation Vacuum super-insulation tions as with the traditional system. The extracted gas is • Local use in fuel cells is an idea worth pursuing and this (connected to H2 tank) heated by the high-pressure gas in the heat exchanger. By is currently being tested at the Heerstrasse site. Ø x H 250 x 6.500 mm extracting the low-pressure hydrogen after the heat ex- • It is also possible to reliquefy the gas locally. Tests are (9.8 ins x 21.3 ft) changer, the ratio of flows of gas in the heat exchanger is currently taking place at the Messedamm site to examine Compressor station altered.As a result, more energy can be transferred from the this idea. Running time 14 h/day high-pressure hydrogen (smaller mass flow) to the low-pres- Dimensions L x W x H 540 x 500 x 990 mm sure hydrogen (larger mass flow). The limits of this process (21.2 x 19.7 x 39 ins) depend on the heat exchanger and the initial temperature Noise development 45 dbA 5 m (16.4 ft) away of the fresh low-pressure hydrogen (tank pressure).The ratio 6.1.3.1 | …What Is Happening to It Drive power can be steered using the low-pressure hydrogen extraction on Messedamm … for the compressor approx. 2.5 kW process. After the heat exchanger, the flow of gas is separated Low-pressure extraction: into gas for consumption and process gas. The compressor The gaseous hydrogen resulting from boil-off is not being Hydrogen before and the ambient air cooling unit are the same as those used directly used for refuelling purposes at the Messedamm site compressor station 20% of the boil-off amount for the normal reliquefaction process.The process gas is fed in order not to interfere with the long-term testing and to the heat exchanger after the air cooler. It is cooled by the demonstration operations of the electrolyser. Instead, the low-pressure gas that enters. A simple throttle device can the station.Any surplus electricity is fed into the grid accord- CEP is testing a new procedure for the very first time: local be inserted behind the heat exchanger. This expands the ing to renewable energy feed-in tariffs. reliquefaction using the LOPEX process, which has been Statement high-pressure gas isenthalpically to the desired tank pressure. developed within the scope of the project. During the expansion process, one part of the process gas Various utilization concepts are being pursued with the two Peter Winkler (Linde, Munich), liquefies. The gaseous part is fed back into the process. The fuel cells. The air-cooled fuel cell made by Axane has been Traditional reliquefaction processes largely consist of a heat the Partner Responsible for the LH2 System lower energy levels after the heat exchanger mean that it is optimized to convert the LH2 boil-off into electrical energy. exchanger,a compressor,an ambient air cooling unit and an possible to expand the gas isenthalpically and produce an The water-cooled fuel cell made by HPS primarily serves to expansion machine. The removal of hydrogen from the gas Field Report on the LOPEX system adequate liquid fraction in contrast to the traditional process. use waste heat to warm up the fuelling station store. Both phase supplies hydrogen at tank pressure and the appropri- Two (competing) systems are being used to store or pro- fuel cells were commissioned in April 2007 after an extensive ate boiling temperature (e.g. at 3 bar [44 psi], T = 24 K). The duce hydrogen in line with the focus of the CEP project. The advantages of LOPEX are: test phase. gas that is extracted is heated in the heat exchanger. An Very low-temperature liquefied hydrogen (- 253°C/- 423°F) • It increases the overall degree of efficiency, exchange of energy takes place between the fresh low- is delivered by fuel truck for refuelling LH2 vehicles and the • It produces a higher liquid fraction after the expansion pressure hydrogen and the high-pressure hydrogen. The fuel is kept in a double-skinned vacuum-insulated storage process, two flows of materials have the same volume.As a result, the tank. The hydrogen for refuelling GH2 vehicles (fuel cell • It provides the option of isenthalpic expansion with a liq- 6.2 | Driving with Hydrogen … energy can only be exchanged on a 1:1 basis. A compressor vehicles with a storage tank at 350 bar [5,080 psi]) is pro- uid fraction, is arranged behind the heat exchanger. This brings the duced locally using an electrolyser. One of the aims of the • Its avoidance of large mass flows (for profitable operations), Sufficiently large vehicle fleets and high mileage are essen- process gas to the desired process pressure. The heat that CEP is to discover a procedure for handling boil-off that is • Its simpler design as a result of doing away with the rela- tial if a highly developed and efficient refuelling infrastruc- occurs as a result is discharged using an ambient air cooling viable within the LH2 system. The boil-off should not be tively complicated expansion machine, ture is going to be tested. Even if the construction of the unit downstream. After passing through the ambient air used to refuel vehicles running on compressed gas. • Its simpler control of the reliquefaction process, vehicles and operating them were not subsidized within cooling unit, the process gas is fed back to the counterflow • The omission of complicated steering units like transaxle the first phase of the CEP project, it was possible to start heat exchanger. It is cooled there by the low-pressure gas Linde has developed the LOw-Pressure-EXpansion process systems or drives, using the first vehicles in Berlin immediately after the open- that enters the system.In order to liquefy the gas,it is brought (LOPEX) with the aim of reducing boil-off losses as far as • The possibility of operating without any outside energy ing of the Aral gas station on Messedamm in November up to tank pressure using an expansion machine.The expan- possible within the CEP; this system should enable an 80% source (e.g. topping up a fuel cell directly from the low- 2004. The handing over to customers was completed grad- sion machine works using isentropic expansion.One part of reliquefaction of the boil-off gases. The process has been pressure hydrogen extraction point). ually in 2005. By mid-2005, when normal operations began the process gas is liquefied as a result. The gaseous part is optimized in real conditions during the course of the proj- at the fuelling station on Messedamm, the planned number fed back into the process behind the expansion machine. ect and the experience gained suggests that this aim is of 16 vehicles on average was reached for the very first time. achievable with the help of the LOPEX system. When Volkswagen AG joined the project in July 2006, anoth- The hydrogen reliquefier with LOw Pressure EXtraction 6.1.3.2 | …And What Is Happening to It er vehicle was added to the fleet testing operations. (LOPEX),which is used on Messedamm,also consists of a heat Further experience within the CEP (at the TOTAL fuelling on Heerstrasse exchanger, a compressor and an ambient air cooling unit. In station on Heerstrasse) has shown that an intelligent boil- The following customers have integrated these cars in their addition, it has a low-pressure hydrogen extraction point off management system can achieve better results at a far Any boil-off is used at the TOTAL refuelling station in two vehicle fleets and are testing them in everyday situations on after the heat exchanger.Low-pressure hydrogen is extracted lower cost using the current configuration.This means that stationary fuel cells which were installed in cooperation a daily basis: from the process at this point. In order to expand the pro- the complete avoidance of any boil-off is feasible. with Vattenfall Europe as part of the EU-funded HyFLEET:CUTE • The Federal Chancellor’s Office cess gas to tank pressure, a throttle device is used in the project.The fuel cells generate heat and electricity for use at • The Federal Ministry of Transport,Building and Urban Affairs 32 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 33

Figure 4: Boil-off management system at the TOTAL fuelling station, © TOTAL Statement Info CEP Mobility Group Always Present in the Berlin City Scene: The 17 Permanent CEP Cars

Field Report on the Vehicles CEP Partner Model Number Drive technology Fuel (State) On average, 17 hydrogen-powered vehicles have been only issue sparking slight criticism is the vehicles’ range used in the test fleet operations in Berlin by the CEP (which is between 150 and 300 kilometers [93 – 186 miles] BMW Group Hydrogen7 2 Internal combustion engine LH2

project partners in the automobile industry within the depending on the vehicle in question). The mobility Daimler AG Daimler F-Cell based on the A-Class 10 Fuel cell CGH2 Clean Energy Partnership. Up to 24 vehicles have been group also positively welcomed the idea of a joint serv- Ford Hybrid Ford Focus Fuel Cell vehicle 3 Fuel cell CGH2 used at peak times. From a technical point of view, vari- ice station at the Messedamm site,which was construct- GM/Opel HydroGen3 based on the Zafira 1 Fuel cell LH ous vehicle concepts are in use:on average two vehicles ed as part of the CEP project and is available to all the 2 operate with a hydrogen-powered internal combustion mobility partners in equal measure for servicing, repairs Volkswagen AG Touran HyMotion 1 Fuel cell GH2 engine and there are 15 fuel cell vehicles – where three and transmitting data. vehicles are driven by liquid hydrogen and 14 use compressed, gaseous hydrogen (at 350 bar/5,080 psi) as The mobility group believes that there is room for im- • The Federal Ministry of Economics and Technology This gives the car a range of more than 200 kilometers (124 their fuel. The vehicles used have traveled a total of provement particularly with regard to communications • The Berlin Public Transit System (BVG) miles) when running on hydrogen. A gasoline tank increases 374,000 kilometers (232,000 miles) in Berlin city traffic between the infrastructure and vehicles users (e.g. in • The Berlin Sanitation Department (BSR) the vehicle’s range by a further 500 kilometers (310 miles). and in the surrounding area without any noteworthy the form of a hotline or an automatic registration sys- • German Telekom (T-Com and T-Systems) incidents within the lifetime of the project. This means tem if breakdowns emerge on the infrastructure side), • Hermes Logistik The BMW limousine can hold its own against the competi- that the CEP project has provided valuable figures relat- an improved range for the vehicles in conjunction with • IKEA tion: It can be used in everyday situations and it is dynamic, ed to the everyday use of hydrogen-powered and fuel a higher density of fuelling stations or improving the • Vattenfall Europe comfortable and safe. It is the world’s first series hydrogen cell vehicles with the aim of pushing ahead with efforts location of the hydrogen fuelling stations and the need • VW dealership limousine in the premium sector. The BMW Hydrogen7 has for future developments based on this knowledge. for a responsible office locally to deal with any unfore- been handed out to customers since 2007. seen problems. The BMW Hyrogen7 has a modified power train, which can The very high availability level of the vehicles and their run on either liquid hydrogen or gasoline. BMW has delib- The A-Class F-Cell from Daimler AG is the result of intense low breakdown rate has been welcomed as a positive In conclusion,we in the mobility group would like to say erately chosen the internal combustion engine with its research work and it represents the sixth generation of development. In particular, the vehicles’ suitability for that the CEP has been highly successful; this is particu- decade-long development experience and which can also Mercedes-Benz fuel cell vehicles. The vehicle has outgrown everyday use should be underlined here – none of the larly evident because the hydrogen-powered and fuel be powered optionally by conventional fuel while the the research stage and is one of the first fuel cell vehicles to drivers (who were largely lay people in relation to cell vehicles that are being used are clearly ready for hydrogen-infrastructure is still in the development stage. go into series production in the world, albeit at a very low hydrogen) have had any misgivings or major problems everyday operations and because the vehicle drivers The 12-cylinder BMW engine develops 192 kilowatts (257 hp) level (60 cars). The A-Class F-Cell is currently proving that it operating the vehicles in Berlin city traffic.The feedback involved are so satisfied; this will pave the way for the and maximum torque of 390 Nm (228 lb ft). The car has a is suitable for everyday use in international cooperation proj- obtained from the customers (drivers) by means of a continuation of the “Using Hydrogen for Road Traffic” top speed of 230 km/h (143 mph). Its highly insulated tank ects in Europe,the USA,Japan and Singapore.The Mercedes questionnaire has also been extremely positive. The success story. has a volume of 170 liters (44.90 gallons) and contains approx. is an ideal city car – quiet, energy-saving, safe and com- 8 kg (17.6 lbs) of liquid hydrogen (LH2) at -253°C/-423°F. pletely emission-free. 34 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 35

Statement Statement Statement Statement

Thomas Opitz, BMW, Joachim Pilz,T-Systems, Renate Lemke, Berlin Georg Hellwig, IKEA, Driver of a Hydrogen Car Driver of a Hydrogen Car City Cleaning Service, Hydrogen Car Driver Hydrogen Car Driver Field Report on the BMW Field Report on the Mercedes F-Cell Field Report Hydrogen7 The way the car drives is awesome.You are always the Field Report on the Ford on the HydroGen3 I have been driving the hydro- first to get away from the stoplight, regardless of who Focus Fuel Cell Vehicle The HydroGen3 is used when gen car every day for almost is next to you. And then there is the environmentally- Testing innovative vehicle I have to travel to customers two-and-a-half years and I have friendly fuel, which is produced using renewable technology is one of our daily as part of my outside work in never had any technical prob- energy sources – I would recommend that anyone tasks, even if the vehicles customer services at IKEA. It lems or other difficulties which takes part in this project.The only thing that disturbs used by the sanitation depart- is used two or three days a have stopped me traveling. me at the moment is the fan which is somewhat loud- ments are normally larger. week so that we can carry When I was asked at the beginning whether I wanted to er than the internal noise on a diesel car when the car The fuel cell Focus has triggered a great deal of excite- out minor repairs at our customer premises and take part in the project as a driver, I was skeptical about is not moving. ment at our company – and not just because of its record customer complaints. If we fill the tank, the car whether the technology in this sector was sufficiently fantastic acceleration at an intersection. We drive the can cover a radius of approx. 200 kilometers (124 advanced to cope with everyday demands.But the vehi- I have never had any misgivings about driving the vehicle almost every day – sometimes there is a small miles) and this covers the whole of Berlin. Although I cle has proved the point – it drives just like a normal car. vehicle. I only prefer to use a different car if I have to argument about which of us colleagues is allowed to was very skeptical about hydrogen and fuel cells,I can In the future I would like to see somewhat shorter refu- drive for quite a distance (more than 100 km [62 drive “the future.” now recommend this new environmentally-friendly elling times for L miles] outside Berlin). technology without any misgivings after two-and-a- H2 and the position of the car at the dispenser made easier.But I am confident that the partners I myself drive the vehicle about two or three times a half years of test driving. Just about anybody could in the project will manage to sort this out. week and I am very satisfied. We have not had many handle this vehicle, I think – apart from the refuelling problems with refuelling and if they have occurred, operations. the staff members at the Aral fuelling station are very ready to help.We have been able to combine the long The Ford Focus Fuel Cell Vehicle is the fifth generation of drive to the fuelling station with a long journey to fuel cell cars from the Ford Motor Company.The model has company headquarters. The F-Cell uses hydrogen in compressed gas form – it is passed the prototype phase and has progressed to the of its drive system are concentrated in a compact module.This compressed to 350 bar (5,080 psi). This means that the car small series production stage as a safe vehicle suitable for is pre-assembled as on a conventional vehicle and is then con- has a range of about 170 kilometers (105 miles). Con- everyday use. nected to the bodywork – as with the normal production of sumption is the equivalent of 4 liters (1.05 gallons) of diesel automobiles. All the drive components are accommodated per 100 kilometers (62 miles). The electric motor has a Its fuel cell system provides 68 kW (91 hp) of electrical electrical energy when it brakes.The engine can then be used under the hood or the rear seat. The size of the interior and power output of 65 kW (87 hp) and develops maximum power.But the hybrid drive system is what gives the Ford its as a generator for a short time and tops up the battery for trunk of the HydroGen3 largely match that of a series produc- torque of 210 Nm (155 lb ft).The F-Cell accelerates from 0 to particular dynamics: A battery provides extra power for the next acceleration maneuver. Thanks to this economic tion Zafira. 100 km/h (0 – 62 mph) in about 14 seconds. Its top speed is acceleration. This powerful combination significantly ups technology, the Ford can cover more than 300 kilometers about 140 km/h (87 mph). The fuel cell system is located in the nominal output of the fuel cell system. The maximum (186 miles) on a tank full of gaseous hydrogen. The HydroGen3 accelerations from 0 to 100 km/h (0 – 62 mph) the sandwich design floor of the A-Class with its long wheel torque of the Ecostar electric motor is the same as that of a in 16 seconds and has a maximum speed of 160 km/h (100 base. So the complete interior is available for passengers 170 hp gasoline engine.The level of efficiency is also extreme- GM/Opel has developed a fuel cell vehicle in the shape of the mph).It can handle all the demands made on the vehicle with- and baggage. ly high. The car’s momentum is fed back into the system as HydroGen3, based on its Zafira model.The main components out an additional reserve battery thanks to the dynamic fuel 36 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 37

cell system.The “HydroGen3 liquid”model is used in Berlin and it has a range of about 400 kilometers (248 miles) with its 4.6 kg (10 lbs) of very low-temperature liquid hydrogen in its tank.

The VW Touran HyMotion is the latest development in vehicles with a fuel cell drive system at Volkswagen.Based on the Touran, the vehicle was developed at the Volkswagen Tech- nology Center in Isenbüttel and was initially tested in everyday working conditions in the USA.Its involvement within the CEP marks its debut in Germany. The Touran HyMotion has a fuel cell drive system.The electric motor has a high degree of torque in a wide range of engine speeds and provides a comfortable driving experience that is free of any vibration. The Statement HyMotion accelerates from 0 to 100 km/h (0 – 62 mph) in 14 seconds. Its top speed is 140 km/h (87 mph).The hydrogen is Martin Kröning, carried in gaseous form at 350 bar (5,080 psi).The fuel cell has Volkswagen Dealer, a maximum electric output of 85 kW (114 hp). The HyMotion Hydrogen Car Driver has a nickel metal hybrid battery with an energy content of 1.9 kWh, which enables it to respond dynamically to the high- Field Report on the est demands placed on it. The car meets the German Techni- VW Touran HyMotion cal Inspection Agency and EIHP guidelines and is as safe as a I have been driving a hydro- Touran with a conventional drive system. gen-powered car for about a year. After everything sorted Continual normal operations with the vehicles began when itself out very quickly, I can the fuelling station on Messedamm moved from test to nor- now say that my initial mis- mal operations during the summer of 2005. At the same time givings particularly with regard to the vehicle’s safety Refuelling with hydrogen twice in Berlin: Layout of the CEP fuelling stations on Messedamm and Heerstrasse an extensive process of collecting data on refuelling and were unfounded.It has now become an everyday rou- vehicle operations began in close cooperation with the tine and I sometimes take my customers at the deal- fuelling station operators and the vehicle manufacturers. ership on journeys with me and show them what a great drive it is.The customers are very interested and ask detailed questions about the technical specifications of the hydrogen vehicle. Overall I can say that July-Dec Jan-June July-Dec Jan-June 2005 2006 2006 2006 the level of public interest in the vehicle and the subject of hydrogen is enormous. Do I have any sugges- Distance 51,000 103,000 145,000 75,000 tions for improvements? The fuelling stations could be traveled km/ km/ km/ km/ a bit more fault-tolerant, because every now and again (estimated 31,620 63,860 89,900 46,500 you are a little uncertain about how to use the hydro- figure) miles miles miles miles gen dispensers as a newcomer to hydrogen. Number of vehicles (in 15 21 24 23 total) 38 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 39

6.2.2 | Reliable Mobility:The CEP Service Stations

Some of the vehicles used in the CEP project are exposed to enormous strain during their everyday operations at the hands of customers. So vehicle maintenance and care are absolutely essential on a daily basis.

The BMW Group, Daimler AG, Ford, GM/Opel and Volkswa- gen AG have been jointly using a car service station with six employees since the spring of 2005; this shop was developed and constructed in close cooperation with an external investor, the International Bus Station Operating Company (IOB). This operating concept is groundbreaking, because it illustrates that hydrogen is already an attractive future proposition for investors now.

En route in Berlin with hydrogen, © TOTAL The Hamburg Hydrogen Project HH2 visits Berlin: view from the CITARO Fuel Refuelling a hydrogen bus, © TOTAL Cell Bus at the opening of the TOTAL fuelling station, March 2006, © TOTAL All the repair work including vehicle inertization, routine checks and functional tests are carried out here.The service station can also be used for demonstration or training purposes. The vehicle data collected here provide important 6.2.1 | En Route:The Berlin Public Transit ation of vehicles, which will begin operations on routes in results about the way the vehicles perform in customer All the components, which have to remain active in a main System (BVG) Successfully Uses Hydrogen- November 2007, are equipped with 200 kW (268 hp) tur- hands. alarm situation, are designed to be explosion-proof. All the Powered Buses on Local Passenger Routes bocharged engines. other components are de-energized at all poles if the main The service station was constructed between September alarm is triggered. Hydrogen on Berlin’s streets: The vehicles in the CEP have Both the operators and customers are satisfied with the 2004 and February 2005. A joint safety concept was drawn not been the only ones since June 2006. The Berlin Public new environmentally-friendly services provided by the up by the safety experts at the mobility partners involved All the conductible units and components are connected to Transit System is gradually putting a total of 14 hydrogen BVG. The vehicles had covered approx. 100,000 kilometers based on existing safety concepts and experience.This was the potential equalization system on the building side. The buses into service between June 2006 and the spring of (62,000 miles) in about a year to 30 June 2007. turned into a standard document for completing the safety service station floor has a conductible coating and is also 2008 as part of the EU-funded HyFLEET:CUTE Project.Another installations in the form of a safety matrix that was agreed connected to the potential equalization system.The gas warn- vehicle – a hybrid bus with an internal combustion engine with the authorizing bodies. ing unit and central fire alarm system are supplied with adapted for hydrogen, a fuel cell and a hybrid option – was power that cannot be interrupted. put into service at the end of 2006 as part of a project spon- Bus Distance covered Commissioned The shop has a conventional technical ventilation system sored by the Federal Ministry of Economics and Technology. 1 31,039 km/19,244 miles June 2006 with a three-fold change of air according to the require- Since it was commissioned, the service station has been The close level of cooperation between the CEP and ments of the workshop directive, but it also has an explo- used by all the partners regularly for servicing, training and HyFLEET:CUTE, which is not only reflected in the construc- 2 28,077 km/17,407 miles June 2006 sion-proof emergency exhaust air unit, which guarantees a demonstration activities.Thanks to the lack of any partitions tion of the fuelling station on Heerstrasse that was funded 3 21,686 km/13,445 miles Oct. 2006 change of air fifteen times with suction equipment in the between the workplaces,designated experts can continual- jointly by both projects, serves both sides. The buses with 4 17,633 km/10,932 miles Oct. 2006 ceiling area.There are facilities in the floor to guarantee the ly exchange ideas about this highly promising technology their high daily mileage and high consumption per mile (in replenishment of air from outside. of the future. The service station has been used on about comparison to cars) guarantee that the ongoing demand Gesamt 98,435 km/61,030 miles June 2006 220 days since it was opened. for fuel is high and therefore the equipment is subject Table 4: Distances covered by hydrogen buses (by 1July 2007) Pneumatically driven roof lights provide the necessary safe- to constant use. The hydrogen production equipment in ty in an emergency involving hydrogen if the emergency Buses in particular, which cover enormous distances, need particular, like the LPG reformer at the Heerstrasse site, ventilation system or power fails at the same time. regular servicing and maintenance cycles. The Berlin Public requires constant operating conditions in order to be able Transit System (BVG) initially equipped its site in Usedomer to work efficiently. The fact that the buses are certain to A study by the Technical University of Berlin shows that the All the workplaces are equipped with the vehicle exhaust Strasse in Berlin’s Wedding district within the CEP. An ex- refuel a certain volume forms the ideal platform for operat- majority of BVG customers support the use of hydrogen- gas suction units normally found in service stations in an isting service station has been equipped with the necessary ing the plant in a cost-effective manner. powered buses on local public passenger services. 86% of explosion-proof design. Two passive stainless steel funnels gas warning and ventilation technology before the move to Berlin users said that they would even agree to higher prices protrude two meters above the roof gable at each workplace. larger real estate, which became necessary with the start of Six buses are now in service.The two vehicles that were put as part of the acceptance study within the HyFLEET:CUTE A gas warning unit has been installed in the shop and reacts HyFLEET:CUTE, led to the construction of a completely new into service in June 2006 were followed by two other buses Project if hydrogen could be used as an environmentally- with two alarm levels: A preliminary alarm is triggered at service station exclusively for hydrogen buses at the Berlin of the same type in October 2006. They are buses with 150 friendly fuel.The BVG is complying with this wish and is put- 20% of the lower explosion limit (LEL) and the main alarm Heerstrasse project site. kW (210 hp) naturally aspirated engines.The second gener- ting another ten buses into service in the short term. goes off at 40% of the LEL. 40 The CEP 2003-2007: Five Years of Mobility with Hydrogen The CEP 2003-2007: Five Years of Mobility with Hydrogen 41

sites and the responsible authorities and all the component parts in contact with hydrogen are being continually monitored, the capacity of existing emergency plans and reporting chains has been clearly proved in various emergency exercises where outside bodies – the authorities and emergency services – have participated.As a result of three years of operating experience,convincing evidence has been provided that hydrogen is a fuel that can be handled safely. It is as safe as any other fuel.

The CEP has focused particular attention on a subject which has attracted little attention in the past, but which must form the focus of interest as the number of hydrogen vehicles and the need for servicing increase – the subject of safety at service stations.

The TOTAL fuelling station on Heerstrasse supplies the hydrogen for the buses The CEP recognized the prime importance and relevance of The information center at the Aral fuelling station on Messedamm has been a from the BVG and the European HyFLEET:CUTE Project, © TOTAL popular attraction for groups of visitors from all over the world since it was this subject at an early stage and formed a working group opened in 2004. with various employers’ liability insurance associations – in this area the active partners in the CEP – Daimler AG, Ford, BMW, GM/Opel and Volkswagen AG – have been joined by The construction of this new service station with two servicing other vehicle manufacturers. 6.4 | Discovering More about Hydrogen manufacturers operate in a showroom that can be viewed areas for standard and articulated buses has been jointly from outside. Both the cells were funded as part of the subsidized by funds from the two projects – HyFLEET:CUTE The working group is led by the expert committee for The CEP has provided hands-on experience with hydrogen HyFLEET:CUTE Project. The cells use one part of the hydro- and CEP.It is a groundbreaking development for joint inter- vehicle maintenance of the BG Metall Nord (North Metal technology since the opening of the Aral fuelling station on gen produced by the reformer to generate power and heat. national attempts to establish hydrogen as the fuel of the Employers’Liability Insurance Association) and is drawing up Messedamm in Berlin – in the true sense of the word – for a Because the number of vehicles traveling in the region at future in Germany and Europe. binding rules governing the handling of hydrogen in vehicle hydrogen information center was opened at the same time the moment is not huge, amounts of fuel cannot always be service stations.The employers’liability insurance association as the inauguration ceremony for the fuelling station in forecast accurately. The fuel cells form a good opportunity for streetcars, subways and railroads (BG BAHNEN) is also November 2004. of using the temporary excess supply of hydrogen in a sen- 6.3 | Hydrogen: A Safe Fuel part of this group.The rules being prepared will be entered sible manner. Guided tours are possible at this center too at in the employers’ liability insurance association manuals Well over 3,000 visitors have seized the opportunity since any time. Traffic accidents are as old as road traffic itself and despite and will form a basis for the state rules which will be fol- then to discover more about hydrogen as a fuel at this cen- all the safety technology available today, they cannot be lowed by all. ter.Many exhibits and tables provide a descriptive overview completely ruled out. So as the number of hydrogen vehi- of the current state of the technology. A guided tour is pos- cles increases,it becomes more likely that they will be involved Based on an evaluation of the situation, a case study was sible at any time if a request is made in advance – whether in traffic accidents too. It is good if the emergency services commissioned and this report has now been completed. It for school groups, experts, the media or politicians. are prepared to intervene in a rapid, safe and dependable contains detailed information on the global state of hydro- manner. Hydrogen is not any more dangerous than other gen safety. But the information gathered so far is not yet Interested visitors can find out about the latest technology fuels. But it does have certain peculiarities like all other sufficient to be able to draw up final safety rules. So experi- in action at the Heerstrasse site.Two fuel cells from different gaseous fuels which have to be taken into account in emer- ments are being carried out to discover just how much gency situations.The CEP therefore sought to make contact hydrogen has to escape to be classified as dangerous. A sit- with the fire department in Berlin at a very early stage and uation has to be simulated where residual gas escapes from has provided detailed information about handling hydro- the pipes in a service station with a normal three-fold Many radio and television reports and the huge interest shown by visitors at public events demonstrate that hydrogen is “in”! gen-powered vehicles at various training sessions. The CEP change of air facility.The appropriate rules will be formulat- has also actively participated in national fire department ed in a binding fashion after the experiments have been conferences and sensitized the emergency services across completed. the country to this issue.

The CEP fuelling stations also meet the highest safety requirements. While detailed alarm plans have been developed in close cooperation with the partners active at the 42 The CEP after 2007

7 | The CEP after 2007

The CEP 2008-2016: This is the continuation of a successful The project will not only demonstrate hydrogen-powered Imprint project that was tested between 2003 and 2007. Joining vehicles for individual traffic (cars) in the upcoming project forces with new strong partners, the goal of the Clean Ener- phases, but it will also show how fleets of hydrogen buses Publisher gy Partnership continues to be pushing ahead with tapping can be managed. The demand for hydrogen that is generat- Clean Energy Partnership into the energy carrier hydrogen and testing its everyday ed by testing buses has particular implications for issues [email protected] suitability and ability to cope with other systems. related to the supply of hydrogen – issues which the CEP www.cep-berlin.de will tackle with a special level of commitment in the future. While the first phase of the project concentrated on The supply of hydrogen will no longer remain a subject con- Text demonstrating that hydrogen can be used safely in road fined to local conditions in the future – answers to the mat- MVV Consulting GmbH, Berlin traffic situations,plans for the future expansion of the scheme ter of providing a sustainable hydrogen-based economy iserundschmidt Kreativagentur für PublicRelations, Bonn - Berlin will embrace two phases with different focuses. will need to be answered regionally, nationally and even Graphic design: internationally. As a result, there are plans to expand the iserundschmidt Kreativagentur für PublicRelations, Bonn - Berlin The second phase of the project (from 2008 till 2010) will CEP to include the city of Hamburg in the long term. concentrate on validating technology in everyday conditions Print and will particularly push ahead with the further develop- The CEP should become an integral part of the National Elch Graphics, Berlin ment of technologies that are essential for hydrogen’s mar- Hydrogen and Fuel Cell Technology Innovation Program ket entry at a later date. This will be followed by the third (NIP) in the future.The CEP will be an important element for Picture credit phase of the project (2011 – 2016), which will be dedicated achieving the defined goals in the program in the traffic Fotos and Illustrations are, unless otherwise noted, copyright by CEP to preparing for the market entry of hydrogen in the traffic sector.These include: sector. • Identifying and overcoming obstacles to commercializing the product, Technological development and validation goals for the • Expanding car and bus fleets, coming phases of the project include the following: • Extending the infrastructure and • Establishing and testing equipment to store and refuel • Increasingly involving renewable energy sources in the with gaseous hydrogen at 700 bar (10,150 psi). production of hydrogen. • Testing this new pressure level in vehicles from various manufacturers and increasing vehicles’ range as a result; The project will also provide important contributions on the this is necessary if the product is going to be a commer- major subjects spearheaded by the NIP: cial success. • Initial and further training, • Developing and testing precise processes for measuring • Communications and volumes of hydrogen which can be calibrated; this is • Establishing rules and standards. essential in the light of the commercial use of hydrogen as a fuel. The Clean Energy Partnership is a flagship project within • Developing viable monitoring systems for customers the demonstration activities of the NIP. who are refuelling and • Further developing and testing the management of boil-

off from LH2.