Low Cost, Metal Hydride Based Hydrogen Storage System for Forklift Applications (Phase II) Adrian Narvaez Hawaii Hydrogen Carriers US DOE Annual Merit Review Meeting June 18, 2014 Project ID: ST 095 This presentation does not contain any proprietary, confidential, or otherwise restricted information Overview Timeline Barriers - Start Date: August 2012 A. System Weight and Volume - End Date: November 2014 B. System Cost - Percent Complete: 75% D. Durability/Operability E. Charging/Discharging Rates I. Dispensing Technology J. Thermal Management Budget Partners - Total Funding Spent as of 3/31/14: - Sandia National Laboratory (SNL) $531,195 Simulations and Single-Tube Testing - Total Project Value: $1,099,526 - Hydrogenics Fuel Cell Integration and Reservoir Testing 2 RelevanceRelevance Main Focus: Prove metal hydride solid state (MHSS) based systems provide a cost competitive, favorable H2 storage option for zero-emission, low-speed material handling vehicles (e.g., forklifts) for industrial applications. Forklifts provide a means to incorporate fuel-cells and metal hydrides as onboard reversible fuel storage Objectives (Sept. 2012 to Sept. 2014): 1. Optimize design of the MHSS fuel system for proton exchange membrane (PEM) fuel cell powered forklift applications (Sept. 2012 to May 2013) 2. Test, qualify, and certify the MHSS fuel system design (May 2013 to Nov 2013) 3. Conduct final fabrication and operational testing of the MHSS fuel system within an integrated systems environment (Sept. 2013 to Sept. 2014) Current reporting year Addresses barriers to move toward lower-cost technologies, reliable onboard reversible fuel storage performance, and technology readiness 3 RelevanceRelevance Current project Barriers Battery Powered High-Pressure H2 Tank Fuel-Cell Metal Hydride H2 Tank Fuel-Cell System Forklift System Powered Forklift Powered Forklift A. System Heavy, although it is Fuel storage can be up to 35% less Heavy metal hydride material makes forklift Weight & needed in a forklift to than metal hydride system, need to applications attractive although additional Volume help as a counterbalance add ballast to reach the required ballast is still needed to reach the required weight of a battery pack weight of a battery pack B. System Need chargers and Need high-pressure refueling Market entry into small forklift fleets, Cost battery exchangers (for infrastructure expensive refueling infrastructure not 24/7 units) Current reporting year needed, use typical H2 gas cylinders D. Performance dropoff at Greater power stability and twice the Hydride material can be brought to it’s Durability/Op the end of duty cycle and lifespan of a battery powered fuel-cell original state and storage capacity, can be erability lifespan of batteries easily integrated with PEM fuel cell E. Long recharge times (up Quick filling and discharging of high- The chosen hydride material will be able to Charging/Dis to 16 hrs), loss in pressure tanks, although meet the needs of the PEM fuel cell. <30 charging productivity compression energy is required (5 min charging but faster charging can be Rates min) accomplished through “opportunity refills” I. Dispensing Chargers and battery Inlet ports and specialized nozzles for High-cost infrastructure not required. Only Technology exchangers hydrogen dispensing have already standard compressed gas tanks and been introduced into the market hydrogen pressure regulator J. Thermal No thermal management No thermal management needed for Heat rejection with the radiator/fan from the Management needed for battery 350 bar high-pressure tank PEM fuel cell will meet the heat rejection requirements during fueling. PEM fuel cell provides heat for H2 desorption during use 4 Approach Use the knowledge from Phase I* to design, build, test, qualify, and certify a metal hydride, fuel cell powered forklift. 1. Work with Hydrogenics to develop baseline reservoir dimensions and features to replace the current battery pack 2. Design single hydride tubes w/ SNL to measure hydrogen storage amounts, refill times, durability, discharge ability, and residual capacity at minimum discharge point for varying hydride tube characteristics (hydrogen distribution tube, amount of thermal enhancement material, type of thermal enhancement material) 3. Fabricate tubes, build experimental setup, and perform single hydride tube tests 4. Perform model verification with experimental results 5. After an optimum hydride tube configuration is chosen, design and build overall reservoir in given space inside the forklift power pack 6. Perform reservoir and fuel cell integration test with forklift followed by the on-site operational test *Phase I work included: Current reporting year • metal hydride modeling studies indicating MHSS will operate per specifications for PEM fuel cell powered forklift applications • determining Hy-Stor 208, AB5 hydride material has adequate hydrogen storage properties to be successfully utilized as the basis of the core of the system • manufacturing, cost, and commercialization analysis showed that the solid-state storage system to be build 5 Approach The Hydrogen Storage Engineering Center of Excellence (HSECoE) has studied hydrogen storage in the past. However, transferrable results are limited due to the different focus of work. Topic HSCECoE HHC (Current Study) Comment (Current Reporting Year) Target Light-duty vehicles (10-11 Industrial forklift (1.2 wt.%). Different required material behavior. Need heavy Application wt%). material to provide counterbalance for forklift Status Eliminated work on metal On commercialization Different focus of work. Site demonstration chosen on hydride in FY2012, prior to pathway. Oahu island using already-obtained Air Products H2 addressing gas cylinder packs commercialization aspects. Cooling Internal coolant tubes. External cooled shell. Different physical design. Single tube refill Method experiments proved that the reservoir could be filled in ~30 mins using the fuel cell’s radiator and fan Heating Requires external H2 burner. Heated by fuel cell. Different system design (some cold-start lessons are Method transferrable). Single tube discharge experiments proved that the reservoir can provide the hydrogen flowrate needed by the fuel cell powered forklift. MH thermal Compaction focus. Various Expanded Natural Different approaches and materials – some qualitative conductivity Graphite (ENG) types. transferability. Using ENG as flakes instead of worms. Containment High temperature, high Near-ambient temperature, Different vessel requirements. Results in lower vessel pressure (150 bar). medium pressure (50 bar). hydrogen pressure supply, no need for gas compression system. Cost (project HSECoE funded at $40M; $1.099M SBIR funds. Low- Different ratio of innovative engineering to leveraging and system) reaching system cost project, system, and of off-the-shelf solutions. performance targets was refueling requirements is 6 primary goal. the focus. Approach Milestones and Go/No Go Decision Project Year 1 (Sept 2012 – Sept 2013) Month Milestones and Go/No Go Decision Comments % Completed 4 System and sub-system specification (SSS) Specification list has been written and 100% established confirmed from the experimental metal hydride tube experiments. 6 Hydride testing completed Various refill and discharge scenarios were 100% tested on different hydride tube configurations. One with the best overall performance was chosen for the final reservoir design. 9 Reservoir design and testing completed Hydride tubes and tubing have been welded 100% and hydrostatically tested to 1.5x working pressure. Engineering drawings have been documented. 12 Reservoir fabrication completed Reservoir is completed, will perform leak and 90% cycle testing once reservoir, fuel cell power pack arrives in Hawaii. Go/No Go Decision: Modeling studies must Single tube experiments confirmed the ability 100% show that final design will meet SSS and be of the metal hydride reservoir to power the fully amenable to integration with fuel cell fuel cell without de-rating the forklift. 7 Approach Milestones and Go/No Go Decision Project Year 2 (Sept 2013 – Nov 2014) Month Milestones and Go/No Go Decision Comments % Completed 4 Reservoir-fuel cell integration and testing Bench integration of reservoir with PEM fuel 80% completed cell and integration of PEM fuel cell/MHSS within sub-component frame almost completed 7 Formal Qualification Test (FQT) and Reservoir testing to validate FEA and CFD 0% certification of reservoir completed modeling once unit arrives in Hawaii 8 MHSS/PEMFC/forklift integration completed Crown forklift has been procured and is 10% located in Hawaii. Includes direct comparison between fabricated MHSS PEM fuel cell system and existing high pressure PEM fuel cell and battery power systems 8 Performance data for integrated reservoir Sub-component tests and comparison with 0% and fuel cell disseminated numerical analysis 11 Complete operational test of forklift Currently coordinating the H2 refueling setup 15% with Hickam AFB 12 Performance data for MHSS/PEMFC/forklift Numerical analysis of the full scale systems 0% disseminated integrations tests, standards/certification compliance 13 License and teaming agreements finalized Licenses, teaming agreements, and 0% partnerships with forklift manufacturers 8 AccomplishmentsAccomplishments andand ProgressProgress Metal Hydride Characteristics ® Metal Hydride: Hy-Stor 208 (MmNi4.5Al0.5) • AB5 Alloy A: hydride forming metal (usually a rare earth metal, Mischmetal) B: non-hydride