F-CELL 2011BMW EFFICIENTDYNAMICS HYDROGEN – PROSPECTS AND CHALLENGES.
Tobias Brunner, 27.09.2011
BMW EfficientDynamicsLess emissions. More driving pleasure.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 2
BMW HYDROGEN.30 YEARS OF HYDROGEN R&D AND REAL WORLD EXPERIENCE.
1979 2006
PEMFC (APU)
LH2-Refueling
First LH2-ICE Vehicle
LH2 Refueling Station
LH2 Powered ICE
Hydrogen Storage
CleanEnergy World Tour H2R Hydrogen 76 Generations
First LH2-Test Bench
Advancements in Cryogenic and Direct injection
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 3
BMW HYDROGEN.6 GENERATIONS OF HYDROGEN VEHICLES:FROM DEVELOPMENT TO FLEET USE.
19792006
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 4
BMW HYDROGEN.NUMEROUS LAND-SPEED RECORDS WITH THE H2R RACE CAR SINCE 2004.
The six-liter 12 cylinder hydrogen combustion engine, based on the gasoline power unit featuredin the BMW 760i, developed an output of more than 210 kW or 285 bhp. This accelerated theBMW prototype to 100 km/h in approximately 6 seconds and gave it a top speed of 302,4 km/h (185,52 mph).
The H2R prototype established the following records :
Time in sec - Speed in km/h- Flying-start kilometer : 11,993 - 300,190- Flying-start mile: 19,912 - 290,962- Standing-start 1/8 mile: 9,921 - 72,997- Standing-start ¼ mile: 14,933 - 96,994- Standing-start ½ kilometer: 17,269 - 104,233 - Standing-start mile: 36,725 - 157,757- Standing-start 10 miles: 221,052 - 262,094 - Standing-start kilometer : 26,557 - 135,557- Standing-start 10 kilometers: 146,406 – 245,892
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 5
BMW HYDROGEN.FIRST HYDROGEN VEHICLE WORLD TOURS IN 2001 AND 2002.
•
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 6
BMW HYDROGEN.HYDROGEN 7: FIRST SMALL SERIES HYDROGEN VEHICLE IN CUSTOMER HANDS.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 7
BMW HYDROGEN.CLEAN ENERGY CAMPAIGN TO MAXIMIZE AWARENESS FOR HYDROGEN VEHICLE TECHNOLOGY.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 8
BMW HYDROGEN 7.STORYLINE.
The BMW Hydrogen 7 is the world’s first premium sedan with a bifueled combustion engine.
The Hydrogen 7 has run through the same product development process as other serial vehicles of the BMW Group.
The Hydrogen 7 is the first premium H2 vehicle to be handed over to users.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 9
BMW HYDROGEN 7.BIFUEL INTERNAL COMBUSTION ENGINE PREMIUM SEDAN WITH A MAXIMUM SPEED OF 230 KM/H IN GAZOLINE AND HYDROGEN MODE.
Maximum speed vmax
Acceleration from 0-100 km/h
Range
LH2
Petrol
230 km/h (cut off)
9.5 sec
> 200 km> 500 km
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 10
BMW HYDROGEN 7.CONVERTED THE 7 SERIES TO A BIFUEL CAR.
Vehicle
CFK strengthening in side frame
Hydrogen gas warning system
LH2-fuel tank system
LH2-coupling system
Control System
Boil-off-ManagementSystem
LH2-Storage System
New components
Adapted components
H2-Powertrain
Bifueled internalcombustion engine
Adapted ignition system
Digital Motor Electronics (DME)
H2 mixture generation system
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 11
BMW HYDROGEN 7.FEATURING A SERIES CONVERTED V12 ENGINE WITH 260 HP AT 5100 RPM.
6.0 litres
191 kW (260 bhp) at 5100 rpm
390 Nm at 4300 rpm
External fuel-mixture generation
Direct injection
Bifueled 12-cylinder engine (LH2 / petrol)
Capacity
Maximum output
Maximum torque
H2:
Petrol:
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 12
BMW HYDROGEN 7.FEATURING A FIRST LIQUID HYDROGEN STORAGE WITH A CAPACITY OF 7.8 KG.
Cryogenic (LH2) at approx. - 250 °C
Double-walled
Vacuum super-insulation with Aluminium reflective foil multi-layer insulation
~ 8 kg extractable H2
< 8 minutes
17 h
9 d
Type:
Shape:
Insulation:
Fuel tank capacity:
Refuelling time:
Start Boil-off*:
Autonomy time*:
*Basis: half-full Tank
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 13
BMW HYDROGEN 7.FEATURING A NEW LH2 REFUELING NOZZLE AND BOIL-OFF MANAGEMENT SYSTEM.
Refueling System:
ConsortiumBMW AG, GM, Honda:
Development of a new
nozzle/receptacle
for a LH2 refueling system.
Boil-Off Management System:
development of a new
catalytic boil-off gas
converter system.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 14
BMW EFFICIENTDYNAMICS STRATEGY.4 STEPS TOWARDS EMISSION-FREE MOBILITY.
BMW EfficientDynamicsLess emissions. More Driving Pleasure.
Optimizing:
• Efficiency• Aerodynamics• Lightweight• Energy Management• Road Resistance
ActiveHybrid
ActiveHybrid X6 and Active Hybrid7
BMW i
Battery Electric and Plug-In Hybrid
Hydrogen
Long Range Zero Emission Hydrogen Vehicle
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 15
MOTIVATION FOR HYDROGEN.CO2 REDUCTION TARGETS REQUIRE ZERO EMISSION VEHICLE PORTFOLIOS.
Quelle: EU Hydrogen FCV Coalition.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 16
MOTIVATION FOR HYDROGEN.ZEV STORAGE SYSTEM ENERGY DENSITY FAVORS HYDROGEN …
Sys
tem
en
erg
y d
en
sity
[k
Wh/
kg],
[kW
h/L
]
0
2
1
7
Hydrogen Li-Ion Battery
CcH2350 bar
CGH2700 bar
CGH2350 bar
Gasoline
6.9kWh/L
1.2kWh/L
8.9kWh/kg9
2.0kWh/kg
0.8kWh/L
1.6kWh/kg
0.6kWh/L
2.0kWh/kg
0.25kWh/L
0
0.15kWh/kg
cryogenic ambient
5xsmaller
13x lighter
Potential ZEV Storage Systems(Comparison does not include different drive train efficiencies)
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 17
MOTIVATION FOR HYDROGEN.ZEV FUEL DISPENSING / REFUELING TIME FAVORS HYDROGEN …
0
50
100
150
200
250
300
Gasoline Hydrogen Electricity50KW2 kg/min50 L/min
2000 km/day
240.000 km/day
80.000
km/day
Ra
ng
e o
f o
ne
dis
pe
nse
r [1
03
km /
day]
Potential ZEV Fuels
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 18
MOTIVATION FOR HYDROGEN.H2 REFUELING COST PROJECTED TO BECOME COMPETITIVEIN THE LONG TERM….
0
5
10
15
Delivered at Pump w/o taxes and excisesHydrogen CostEUR/kg
2050204520402035203020252020
4.44.44.5
2015
4.75.05.5
6.6
9.9
2010
16.6
Production
Distribution
Retail
Small retail stations operating
at low utilization
1 kg H2 for ~ 100-120 km
long term ~ 3.5 - 4.5 €-ct /km (w/o tax)(4L/100km Diesel today: 6 €-ct/km incl. tax)
Source: EU Hydrogen FCV Coalition.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 19
MOTIVATION FOR HYDROGEN.... BUT WIDE-SPREAD HYDROGEN INFRASTRUCTURE IS STILL YEARS AHEAD.
Germany
• H2 Mobility: Infrastructure Roll-out towards 2015 under investigation.
• Funding for 20 H2 stations announced by industry partners Daimler & Linde.
Japan
• National hydrogen infrastructure roll-out plan:100 Filling Station towards 2015 around 4 megacity regions.
California / CARB states
• CARB/CEC funds initial Infrastructure build-uptowards 2014-2017.
• Regulation to enforce infrastructure roll-out in line with vehicle deployment under investigation (CFO)
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 20
MOTIVATION FOR HYDROGEN.… BUT PEM FUEL CELL TECHNOLOGY IS STILL TOO COSTLY.
38,565
9,516
6,296
14,274
2010
81,362
20502020
22,228
2015
3,212
4,3067,475
2,970
18,892
3,194
-77%
-42%
-60%
FC stack lifetime [„000 km] 115 180 247 290
Platinum use [g/kW] 0.93 0.44 0.24 0.11
Key drivers for cost reduction
▪ Innovations in design (e.g.,
reducing complexity).
▪ Different use of materials (e.g., reduced platinum use).
▪ Innovations in production
technology.
▪ Economies of scale.
Source: EU Hydrogen FCV Coalition.
Structure
MEA
(excl. catalyst,
incl. GDLs)
Periphery
Catalyst
(incl. platinum)
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 21
BMW ELECTRIC VEHICLE ROLL-OUT.PLUG-IN (HYBRID) ELECTRIC VEHICLES ARE CLOSE TO COMMERCIALIZATION.
MINI E
BMW Concept ActiveE
Fun
ctio
nalit
y &
Mar
keta
bilit
y
2009
BMW i3
2011 2013
BMW i3 Concept 2011
BMW i8
BMW i8 Concept 2011
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 22
BMW HYDROGEN TECHNOLOGY.ADVANCEMENT OF CORE HYDROGEN VEHICLE COMPONENTS.
Advanced key components Next vehicle & infrastructureHydrogen 7 small series
LH2 Storage
Capacity
Safety
Boil-off loss
Pressure supply
Complexity
Infrastructure
Technology Leap Storage & Drive train
Long-range ZEV Mobility:
Zero Emission.
Focus on vehicles with high
energy demand.
Range > 500 km (6-8 kg H2)
Fast refueling (< 4 min / 7 kg)
Optimized safety oriented vehicle package & component integration
Loss-free operation for all
relevant use cases
Compatibility to competitive
infrastructure standards
IC Engine (PFI)
Power density
Dynamics
Durability & cost
Efficiency
H2 Drive train
H2-Storage
Electrification
H2ICE H2HEV EREV FCHV FC-EREV
AdvancementKey Components
CGH2LH2CcH2
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 23
BMW HYDROGEN TECHNOLOGY.HYDROGEN INTERNAL COMBUSTION ENGINE TECHNOLOGY STATUS: DOUBLE POWER DENSITY COMPARED TO HYDROGEN 7 ICE ON TEST BENCH.
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 24
BMW HYDROGEN TECHNOLOGY.STATUS OF SMALL FUEL CELL TECHNOLOGY (5 KW): EFFICIENCY, DYNAMICS, DURABILITY AND FREEZE START VALIDATED.
UTC5KW
PEMFC
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 25
BMW HYDROGEN TECHNOLOGY.STORAGE TECHNOLOGIES: ONLY PHYSICAL STORAGE SYSTEMS VALIDATED FOR USE IN PASSENGER VEHICLE.
Physical Storage Solid storage
Single or multi-
pressure vessel
700 (350) bar
Liquid Adsorption
„activated
carbon“
Hydrides
„MOFs“„chemical“
„Zeolith“„organic“
„metallic“
Compressed
CGH2* LH2
*
Source: BMW
Super-insulated
low-pressure Cryotank
Research level!Demonstration level
Small Series level,
Mainstream
Source: Quantum
CcH2*
Source: BMW
Cryo-compressed
Super-insulatedcryogenic pressure
vessel 350 bar
Prototype level
„organic“
*) CGH2 := Compressed Gaseous Hydrogen (700bar) CcH2 := Cryo-compressed Hydrogen (10bar - 350bar) LH2 := Liquid/Liquefied Hydrogen (1 bar_a - ca. 10 bar_a)
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 26
BMW CRYO-COMPRESSED HYDROGEN STORAGE PROTOYPE 2011.
CRYO-COMPRESSED HYDROGEN STORAGE.
Modular Super-insulated Pressure Vessel (Type 3) to Store Cryogenic Gas
Max. usable capacity
CcH2: 7.8 kg (260 kWh)CGH2: 2.5 kg (83 kWh)
Operating pressure
350 bar
Vent pressure ≥ 350 bar
Refueling pressure
CcH2: 300 barCGH2: 320 bar
Refueling time< 5 min for 7.8kg (equivalent to J2601)
System volume ~ 235 L
System weight (incl. H2)
~ 140 kg
H2-Loss (Leakage| max. loss rate | infr. driver)
<< 3 g/day | 3 – 7 g/h (CcH2) |no significant losses
+ Active tank pressure control
+ Load carrying vehicle body integration
+ Engine/fuel cell waste heat recovery
Vacuumenclosure
Aux. systems(control valve, regulator, sensors)
MLI insulation(in vacuum space) Refueling line
Shut-off valve
Intank heatexchanger
Suspension
Coolant heatexchanger
Pressure Vessel (Type 3)
Secondary vacuum module(shut-off / saftey valves)
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 27
CRYO-COMPRESSED HYDROGEN STORAGE.SIGNIFICANT MAXIMUM CAPACITY ADVANTAGE OVER COMPRESSEDGASEOUS STORAGE AT 700 BAR.
7.8 kg* CcH2
140 kg system**
*) maximum usable H2-mass with 10 bar power train supply pressure. **) based on prototype 2011, including BOT & BOP
Cryo-compressed Hydrogen - CcH2
Com
pre
ssed
Gas
eous
Hyd
roge
n -
CG
H2
2200 mm
346
mmdesign space
> 80% higher max. usable storage
capacity in given design space.
4.3 kg* CGH2
90 kg system
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 28
CRYO-COMPRESSED HYDROGEN STORAGE.SAFETY ASPECTS: DOUBLE LAYER PROTECTIVE DESIGN, REDUNDANT SAFETYDEVICES AND LOW EXPANSION ENERGY EXHIBIT A HIGH SAFETY LEVEL.
Vacuum enclosure & safety release control Low adiabatic expansion energy
Vacuum enclosure design lowers risk of pressure vessel damage (mechanical and chemical intrusion,
bonfire damage and aging) and enables leak monitoring.
Redundant safety devices for controlled hydrogen release in case of damage or vacuum failure.
Cryogenic hydrogen contains a low adiabatic expansion energy and thus, can mitigate implications of a
sudden pressure vessel failure, in particular during refueling.
Ad
iab
atic
exp
ansi
on
en
erg
y [k
Wh
/kg
]
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
CcH2
Full CcH2 storage
after cold refueling
6-15 times
lower expansion
energy
Ambient CGH2
storage after refuelingVacuum Enclosure
Redundant Safety Devices
COPV in vacuum environment
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 29
CRYO-COMPRESSED REFUELING.REFUELING VIA HIGHLY EFFICIENT LH2 HIGH PRESSURE PUMP: DURABILITY VALIDATION RUNNING SINCE 04/2010.
BMW Linde CcH2 pump prototype
80 g/L at 300 bar
100 kg H2/h (status)
< 1% LHVcompression energy
In Operation since04/2010
H2 delivered (07/2011): ~ 30 000 kg (> 6000 refuelings withsubscale and full size tank systems)
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 30
CRYO-COMPRESSED REFUELING.CRYO-COMPRESSED REFUELING UP TO 30 MPA, > 120 KG/H WITH NO NEED FOR COMMUNICATION BETWEEN STATION AND VEHICLE.
Hydraulics
30MPa
Cryo-pump
Quick , direct, non-com refueling to be demonstrated by the end of 2011.
Direct single-flow refueling to
300 bar via cryo-pump
100 -120 kg/h continuous fill rate
( 3 - 3.5 minutes for 6 kg)
No need for communication
between vehicle and dispenser
“… the future for sure is!”
“History can be exciting…”
f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 32
BMW EfficientDynamicsLess emissions. More driving pleasure.