BMW EfficientDynamics Less emissions. More driving pleasure.

Dr. Klaas Kunze, Dr. Oliver Kircher

CRYO-COMPRESSED STORAGE CRYOGENIC CLUSTER DAY, OXFORD, SEPTEMBER 28, 2012 BMW DEVELOPMENT. AGENDA.

 BMW Hydrogen Storage Strategy  Cryocompressed Hydrogen Storage Development  Refueling technology  Compatibility with infrastructure  Conclusion

BMW Hydrogen Storage, September 28th, 2012 Page 2 BMW HYDROGEN STORAGE DEVELOPMENT. AGENDA.

 BMW Hydrogen Storage Strategy  Cryocompressed Hydrogen Storage Development  Refueling technology  Compatibility with infrastructure  Conclusion

BMW Hydrogen Storage, September 28th, 2012 Page 3 BMW EFFICIENT DYNAMICS. 4 STEPS TOWARDS EMISSION-FREE MOBILITY.

BMW EfficientDynamics Less emissions. More Driving Pleasure.

Hydrogen

BMW i Long Range ZEV Mobility ActiveHybrid Battery Electric and Plug-In Hybrid Optimizing: ActiveHybrid X6 and Active

• Efficiency Hybrid7 • Aerodynamics • Lightweight • Energy Management • Road Resistance

BMW Hydrogen Storage, September 28th, 2012 Page 4 BMW HYDROGEN TECHNOLOGY STRATEGY. ADVANCEMENT OF KEY COMPONENTS.

Hydrogen 7 small series Advanced key components Next vehicle & infrastructure

Technology leap storage & drive train Advancement Storage & Drive train

Efficient long-range mobility: H2-Storage LH2 Storage  Zero Emission.  Capacity   Focus on medium & large CGH CcH2 LH2  Safety  2 vehicles with high energy  Boil-off loss  demand.  Pressure supply   Range > 500 km (6-8 kg H2)  Complexity  Source: Quantum Source: BMW Source: BMW  Fast refueling (< 4 min / 6 kg)  Infrastructure   Optimized safety oriented H2 Drive train vehicle package & component V12 PFI engine integration  Power density   Loss-free operation for all  Dynamics  relevant use cases FCHV FC-EREV  Durability & cost  H HEV EREV H2ICE 2  Compatibility to upcoming  Efficiency  Electrification infrastructure standard

BMW Hydrogen Storage, September 28th, 2012 Page 5 BMW HYDROGEN STORAGE. 5 SERIES GT CCH2-FC-HYBRID CONCEPT CAR.

High voltage Customer benefits of battery ~1KWh usable CcH2-storage in Hybrid Vehicle

500 km customer real life, PEM Fuel Cell Range ~90 kW electrical power > 800 km test cycle

Refueling time < 5 min Refueling for 500 km possible

Potentially lower fuel cost due Electrical rear wheel Operating drive to lower investment and costs ~200/ 80 kW operating costs at the station.

H2 Cryo-compressed central tunnel storage Additional cooling from CcH2- max. 7,2 kg usable storage enables better fuel cell Performance power train performance in critical driving situations.

BMW Hydrogen Storage, September 28th, 2012 Page 6 HYDROGEN STORAGE TECHNOLOGIES. ONLY PHYSICAL STORAGE VALIDATED FOR USE IN PASSENGER VEHICLES.

Physical Storage Solid storage

Compressed Cryo-compressed Liquid Hydrides Adsorption

CGH * CcH * LH * 2 2 2 „activated „metallic“ carbon“

Source: Quantum Source: BMW Source: BMW „chemical“ „MOFs“

Single or Super-insulated Super-insulated multi- pressure cryogenic low-pressure „Zeolith“ vessel pressure vessel cryotank 700 (350) bar 350 bar „organic“

Small Series level, Prototype level Demonstration Mainstream level Research level!

*) CGH2 := Compressed Gaseous Hydrogen (700bar) CcH2 := Cryo-compressed Hydrogen (10bar - 350bar) LH2 := Liquid/Liquefied Hydrogen (1 bar_a - ca. 10 bar_a)

BMW Hydrogen Storage, September 28th, 2012 Page 7 BMW HYDROGEN STORAGE . CCH2 – CRYOGENIC GAS DENSER THAN LH2.

100 LH2 90 CcH2 Cryo-compressed Hydrogen 80 80 g/L CGH2 Compressed Gaseous Hydrogen LH2 – 1 CcH2 – 300 bar / 38 K bara 70 +27% 63 g/L x2

60 LH2 – 4 bara

50 [g/L] CGH2 – 700 bar / 288 K

40 40g/L Dichte [g/l] Dichte

LH2 Density 30 CGH2 – 350 bar / 288 K

20

10 CcH2 CGH2 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 33 K Temperature [K] -40°C Temperatur [K] BMW Hydrogen Storage, September 28th, 2012 Page 8 BMW HYDROGEN STORAGE. CCH2 – OPERATING REGIME.

100 LH2 Liquid Hydrogen 90 CcH2 Cryo-compressed Hydrogen Highest possible storage 80 pressure at cryo. conditions CGH2 Compressed Gaseous Hydrogen

70 Refueling (300K, 38K)

60

50

[g/L]

40 Highest possible storage Dichte [g/l] Dichte LH2 pressure at warm conditions (in CGH2 mode) Density 30

20 Extraction to lowest pressure

10 CcH2 CGH2 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 33 K Temperature [K] -40°C Temperatur [K] BMW Hydrogen Storage, September 28th, 2012 Page 9 BMW HYDROGEN STORAGE DEVELOPMENT. AGENDA.

 BMW Hydrogen Storage Strategy  Cryocompressed Hydrogen Storage Development  Refueling technology  Compatibility with infrastructure  Conclusion

BMW Hydrogen Storage, September 28th, 2012 Page 10 CRYO-COMPRESSED HYDROGEN STORAGE. SYSTEM LAYOUT – BMW PROTOTYPE 2011.

Modular Super-insulated Pressure Vessel (Type III)

Max. usable CcH : 7.8 kg (260 kWh) 2 + Active tank pressure control capacity CGH2: 2.5 kg (83 kWh) + Load carrying vehicle body integration Operating  350 bar pressure + Engine/fuel cell waste heat recovery

Vent pressure ≥ 350 bar MLI insulation COPV (Type III) (in vacuum space) Refueling Refueling CcH : 300 bar 2 line Shut-off valve pressure CGH2: 320 bar

Refueling time < 5 min Suspension

System volume ~ 235 L

System weight Vacuum ~ 145 kg (incl. H ) enclosure 2 Intank heat H -Loss (Leakage| << 3 g/day | exchanger 2 Coolant heat max. loss rate | infr. 3 – 7 g/h (CcH2) | Secondary vacuum Aux. systems driver) < 1% / year exchanger (control valve, regulator, module (shut-off / saftey valves) sensors)

BMW Hydrogen Storage, September 28th, 2012 Page 11 STORAGESYSTEM VOLUMECOMPARISON. BMW BMW BMW HydrogenSeptember2012 Storage,28th, Storage system volume [L] 1000 1250 250 500 750 0

CRYO - COMPRESSEDHYDROGENSTORAGE. 5

10

15

kWh 0.4 /L

Max. Max. 20 usable

kWh 1.0 kWh 0.8 kWh 0.6

storage

/L /L /L

capacity 35 35 70

[kgH MPa MPa MPa Page 2

CcH CGH CGH ]

12 2 2 2

BMW CRYO-COMPRESSED HYDROGEN STORAGE. STORAGE SYSTEM WEIGHT COMPARISON.

500 1.0 1.5 70 MPa CGH2

kWh/kg kWh/kg 35 MPa CGH2

[kg] 400 2.0 35 MPa CcH

kWh/kg 2 weight 300 2.5

kWh/kg system

200 Storage Storage 100

0 5 10 15 20 Max. usable storage capacity [kg H2]

BMW Hydrogen Storage, September 28th, 2012 Page 13 CRYO-COMPRESSED HYDROGEN STORAGE. MAIN FUNCTIONS PERFORMANCE.

Refueling densities up to 72 g/L.

High CcH2 density after 3-4 refuelings.

First cold refueling of ambient storage features 30 g/L hydrogen density, second cold refueling more than 50 g/L.

First warm CGH2 refueling of cold storage to 32 MPa results in more than 40 g/L refueling density.

BMW CcH2 test refuelings confirm the predicted values.

BMW Hydrogen Storage, September 28th, 2012 Seite 14 CRYO-COMPRESSED HYDROGEN STORAGE. EXTENDED CCH2 OPERATING REGIME - INCREASED PRESSURE VESSEL REQUIREMENTS.

1000 1 Refueling (300 / 57 K)

currently required burst pressure (2.25 x 350 bar) Highest possible 800 storage pressure at 2 out-baking and vacuum generation cryogenic conditions (subsequent to CcH2 refueling 600 refueling) CGH 350 bar refueling 2 Extraction to lowest 4 3 pressure (subsequent 400 2

to refueling) pressure [bar] pressure 1 Highest possible 350 bar CGH (extended) CcH operating regime 2 storage pressure at 200 2 operating regime 4 warm conditions (in 3 CGH2 mode) 5 0 Out-baking and 0 40 80 120 160 200 240 280 320 360 5 vacuum generation temperature [K] during production

BMW Hydrogen Storage, September 28th, 2012 Page 15 BMW HYDROGEN STORAGE DEVELOPMENT. AGENDA.

 BMW Hydrogen Storage Strategy  Cryocompressed Hydrogen Storage Development  Refueling technology  Compatibility with infrastructure  Conclusion

BMW Hydrogen Storage, September 28th, 2012 Page 16 H2 INFRASTRUCTURE – POTENTIAL ROLE OF CCH2. CRYO-PUMP PERFORMANCE.

BMW Linde CcH2 pump prototype:

 80 g/L at 300 bar

 100 kg H2/h (up to 120 kg/h)  < 1% LHV compression energy  In Operation since 04/2010

 H2 delivered (09/2012): ~ 45,000 kg (> 7000 refuelings with subscale and full size tank systems) Proof of Concept: Function, Durability and Efficiency.

BMW Hydrogen Storage, September 28th, 2012 Page 17

H2-INFRASTRUCTURE. CRYO-COMPRESSED REFUELING.

CcH2- in operation since 11/2011.

 High performance CcH2-quick connector coupling for consecutive refuelings.  Direct single-flow refueling to 30 MPa via cryo-pump

(no buffers required). Cryopump  100 – 120 kg/h continuous fill rate ( 3 – 3.5 minutes for up to 6 kg).  No need for communication between vehicle and dispenser. CcH2-dispenser

Test tank-sytem

CcH2-coupling

BMW Hydrogen Storage, September 28th, 2012 Page 18 H2-INFRASTRUCTURE COMPARISON OF HYDROGEN REFUELING COUPLINGS.

LH2-coupling: H2-fuel Vehicle side Filling station side BMW/Linde/Opel/Walther  Low pressure  Cryogenic temperatures  Double flow (back-gas to Liquid Hydrogen (LH2) station) 0,4 MPa  Ball valves

CcH2-coupling:  Moderate pressure Cryo-compressed / CcH2  Cryogenic temperatures Compressed Gas  Single flow CcH2 30 MPa LH2  Checkvalve on vehicle side

~2 kg H2/min  High filling performance. BMW/Linde/Walther  Online leakage control  Easy to use handling Compressed Gas  Fully automated non-com (CGH2) 70 MPa filling procedure.  Comparable in size to

existing CGH2-couplings. ~2 kg H2/min

WEH

BMW Hydrogen Storage, September 28th, 2012 Page 19 BMW HYDROGEN STORAGE DEVELOPMENT. AGENDA.

 BMW Hydrogen Storage Strategy  Cryocompressed Hydrogen Storage Development  Refueling technology  Compatibility with infrastructure  Conclusion

BMW Hydrogen Storage, September 28th, 2012 Page 20 H2-INFRASTRUCTURE. HYDROGEN COMPRESSION EFFICIENCY.

Energy consumption for compression to CGH2 vs CcH2 at the hydrogen refueling station. 20 GH2 compression (from 20bar) LH2 compression (from 2bar) 18 (ionic compressor) (high-pressure cryo-pump)

16

>10x Cryo compressed LH2 70MPa, 2010 ) 2 14 Higher Cryo compressed LH2 70MPa, 2015 energy

CcH Cryo compressed LH2 30MPa, 2010 12 Large amount of demand demand

high-pressure Cryo compressed LH2 30MPa, 2015 MPa 10 buffers, increasing Pre-cooling CGH2 (-40°C) with number of

energy Ionic Compression CGH2 70MPa

to 30 to

vehicles 8

6 2-3x higher

normalized energy ( Compression 4 demand 2

0 70MPa CGH2 (max.) 70MPa CGH2 (min.) 70 Mpa CGH2 (LH2) 30 Mpa CcH2

BMW Hydrogen Storage, September 28th, 2012 Page 21 H2-INFRASTRUCTURE. HYDROGEN COMPRESSION EFFICIENCY.

Energy demand for liquefaction is nearly being compensated by less effort for compression, aftercooling

and logistics necessary for CGH2-based filling stations. Increasing station size reduces idle time losses.

Source: CGH2 Source: LH2 12 70 MPa CGH2

30 MPa CcH2 10

Aftercooling, idle 8 Aftercooling H2 (-40°C)

Compression LH2 70MPa dispensed 6

2 Compression LH2 30MPa

Compression CGH2 70MPa /kg H /kg 4 Delivery

kWh Liquefaction 2 25MPa 50MPa 0 min. max. min. max. min. max. min. max. 80 kg/d (small) 200 kg/d (medium) 400 kg/d (large) >400 kg/d

BMW Hydrogen Storage, September 28th, 2012 Page 22 BMW CRYO-COMPRESSED HYDROGEN STORAGE. HYDROGEN DISTRIBUTION – ROLE OF LH2.

500 kg GH2 / 3500 kg LH2 / trailer: 3 trailer: 3

times a day times a week

1500 kg H2 / day

H2-Infrastructure forecast: „Cost-effectiveness, station footprint and safety issues will decide on delivery method and station layout“:  Liquid hydrogen distribution at larger stations (> 400 kg/day).

 LH2 distribution & station storage eases integration in existing infrastructure.  Gaseous hydrogen distribution via pipelines might face economic and social challenges even in the long term.  Compressed gas trailers and onsite electrolysis in ramp-up phase, only. Liquid delivery and station storage will play an important role in a future infrastructure.

BMW Hydrogen Storage, September 28th, 2012 Page 23 H2-INFRASTRUCTURE. OPERATION OF LARGE STATIONS WITH LIQUID SUPPLY ECONOMICALLY ADVANTAGEOUS.

Estimated Costs at Filling Station for 70MPa CGH2 outlet - Scenario 2020 * t€/station €/kg H2 dispensed

*

**

80 kg/d 200 kg/d 400 kg/d 1000 kg/d 80 kg/d 200 kg/d 400 kg/d 1000 kg/d

* Fixed opex p.a. w/o electrictiy, incl SG&A (Selling, general and administrative Expenses) ** Currently under quantitative evaluation

BMW Hydrogen Storage, September 28th, 2012 Page 24 H2-INFRASTRUCTURE. FUTURE FILLING STATION LAYOUT FOR CCH2 & CGH2.

Source Production Distribution Filling station SMR Efficient compression and Liquefaction High pressure buffer high scalability. up to 90 Mpa 40 g/L Carbon for SAE J2601 Aftercooler CGH2 CGH2 GH2 LH2 1,5 kg/min Electricity mix (3 MW) 70 MPa EU Elektrolysis LH2 Trailer Heat Exchanger Wind power 69-65 g/L Partial warm up 1,5 – 3 bar Hydropower LH 80 g/L 2 CcH2 Solar energy CcH2 cryogenic high 2 kg/min LH pressure pump 2 (4 MW) Geothermal Station storage 30 MPa energy Cryo-compressed fuel with highest density at Biomass lower pressure. Filling station with LH2-supply and cryogenic high pressure pump. BMW Hydrogen Storage, September 28th, 2012 Page 25 BMW HYDROGEN STORAGE DEVELOPMENT. AGENDA.

 BMW Hydrogen Storage Strategy  Cryocompressed Hydrogen Storage Development  Refueling technology  Compatibility with infrastructure  Conclusion

BMW Hydrogen Storage, September 28th, 2012 Page 26 BMW HYDROGEN STORAGE DEVELOPMENT. CONCLUSION.

LH2 is the solution for large stations (> 400 – 1000 kg/day).

Cryo-compressed H2-storage shows good performance and interesting perspectives for the fueling station business case. Technology risks of cryo-compressed are still high, but no show stopper has been discovered until now.

BMW continues developing CGH2 700 bar and 350 bar CcH2 vehicle storage in parallel.

BMW Hydrogen Storage, September 28th, 2012 Page 27 BMW HYDROGEN STORAGE DEVELOPMENT. ADDITIONAL SLIDES.

BMW Hydrogen Storage, September 28th, 2012 Page 28 CRYO-COMPRESSED HYDROGEN STORAGE. VALIDATION OF STRUCTURAL DURABILITY.

Combined pressure and cryogenic temperature cycling does not to degradation in composite material properties Combined pressure and cryogenic temperature cycling does not lead to degradation of vessel burst pressure & vessel pressure cycle life

 Burst pressure of full scale COPV vessels after 600 CcH2 and 200 CGH2 refuelings stay within statistical spread of virgin vessel burst pressure  Initial virgin pressure cycle life of subscale COPV vessels (13.115 cycles 2 – 43.8 MPa at ambient temperatures) shows only minor degradation after 3.000 CcH2 and 1.000 CGH2 refuelings (1 – 32 MPa)

*) leakage at welded joint

BMW Hydrogen Storage, September 28th, 2012 Page 29 CRYO-COMPRESSED HYDROGEN STORAGE. SAFETY ASPECTS.

Vacuum enclosure & safety release control Low adiabatic expansion energy

1 Ambient CGH storage after Vacuum 6 – 15 times lower 2 expansion energy refueling Redundant Safety Enclosure ] 0,8 Devices 0,6 CcH2

0,4 Full CcH2 storage after cold refueling

0,2

energy [kWh/kg

Adiabatic expansion Adiabatic 0 COPV in vacuum environment

 Vacuum enclosure design lowers risk of pressure vessel damage (mechanical and chemical intrusion, bonfire damaging and aging) and enables leak monitoring.  Redundant safety devices for controlled hydrogen release in case of damage or vacuum failure.  Cryogenic hydrogen contains a fairly low adiabatic expansion energy and thus, can mitigate implications of a sudden pressure vessel failure, in particular during refueling.

CcH2 storage eases vessel monitoring and mitigates failure impact. BMW Hydrogen Storage, September 28th, 2012 Seite 30 CRYO-COMPRESSED HYDROGEN STORAGE. SAFETY – STATUS & SCHEDULED TESTS.

Test Explanation Status

No additional implications compared to vehicle crash with CGH2 storage expected. Vehicle crash Crash Tests will be done during vehicle qualification in 2012/2013.

Vacuum insulation & multiple safety devices (PRDs & TPRDs) lower risk of vessel failure. Vehicle fire Bonfire Local. fire Bonfire test validated in 2011, localized fire test in 2013.

Adiabatic expansion energy in case of sudden vessel failure is mitigated in cryogenic gas storage compared to warm gas storage: Burst energy Simulation: @ T < 100 K liquefaction during expansion supposable Validation: burst test under warm & cryogenic conditions show significant differences

Validation of safe H2-discharge via pressure relief devices (and optional vacuum-casing burst disc) in case of Air- or H - sided vacuum loss. Air 2 Sudden Vacuum Loss Vacuum loss H2 Implication of air-side vacuum-loss is mitigated compared to LH2. Impact damage, Vacuum enclosure lowers risk of pressure vessel damage through external impacts. penetration, chem. Tests will be done during vehicle qualification in 2012/2013. exposure Type III pressure vessel with welded boss, joints & vacuum casing eliminates issue of Permeation and Leakage permeation & mitigates risk of leakage compared to CGH2 storage. Leakage rate << 3g/day.

BMW Hydrogen Storage, September 28th, 2012 Page 31 BMW CRYO-COMPRESSED HYDROGEN STORAGE. USE CASE PROJECTIONS.

8kg reference CcH2 system, 8W heat leak (cost-efficient insulation), 65 mpkg vehicle fuel economy

Long distance: continous driving Auto-adaptive Frequent traveller: 15000 mls / year density Commuter: 10000 mls/year minimizes vent

[g/L] Infrequent driver: 5000 mls/year loss risk, still leaves max.

capacity option. Usable hydrogen density density hydrogen Usable

long distance frequent traveller commuter infrequent driver Storage temperature [K]

BMW Hydrogen Storage, September 28th, 2012 Page 32 BMW CRYO-COMPRESSED HYDROGEN STORAGE. USE CASE PROJECTIONS.

8kg reference CcH2 system, consecutive cold 30 MPa refuelings, constant discharge, ambient dispenser lines

max. extended density (cold dispenser lines) From warm to cold max. density operation

[g/L] with consecutive CcH CGH2 70 MPa equiv.* 2 Start with refuelings. ambient CGH 35 MPa equiv.* 2 storage (steady state 35MPa

CGH2) Usable hydrogen density density hydrogen Usable

refill density (50mls range)

*) equivalent CGH2 storage density in identical package envelope Storage temperature [K]

BMW Hydrogen Storage, September 28th, 2012 Page 33