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Session 3.1: Cryogenic Storage Systems Dr. G. Bartlok 25 th – 29 th September 2006 Ingolstadt
Session 1.2: IntroductoryLectures
K. Hall
Session 3.1: Cryogenic Storage Systems
Dr. G. Bartlok
25th – 29th September 2006Ingolstadt
Session 3.1 Cryogenic Storage Systems G. Bartlok 2
CV – Dr. G. Bartlok
Address:MAGNA STEYREngineeringLiebenauer Hauptstraße 3178041 Graz, AustriaEmail: [email protected]
Guido Bartlok, born 1970 in Frankfurt (Oder) in Germany, received his diploma in mechanical engineering at the Technical University Dresden. The Ph.D. work was done at the cryogenic institute of the TU Dresden. He joined the MAGNA STEYR Fahrzeugtechnik AG & Co KG in 2003. Mr. Bartlok is jointly responsibly for development and production of automotive liquid hydrogen storage systems and research activities (e.g. Project Management of the Subproject Cryogenic Storage within the EU 6th Framework Program IP “StorHy”).
3.1 Cryogenic Storage Systems
Session 3.1 Cryogenic Storage Systems G. Bartlok 3
3.1 Cryogenic Storage Systems
Lectures on Liquid H2 Storage TechnologyDr. G. Bartlok
Abstract:Within this session an overview about liquid H2 storage technology is given. This includes state of the art design, materials, challenges, characterisation techniques, laboratory tools, simulation methods, up-scaling, productionprocess and testing.
Session 3.1 Cryogenic Storage Systems G. Bartlok 4
Source: MAGNA STEYR
Source: Linde Source: Air Liquide
L-H2 Storage System – State of the Art
Session 3.1 Cryogenic Storage Systems G. Bartlok 5
Design Process according to IEC 61508
SpecificationSpecification
Verification &Validation
Verification &Validation
ConceptConcept
PrototypeDesign
PrototypeDesign
PrototypeImplementation
PrototypeImplementation
PrototypeValidation
PrototypeValidation
IntegrationTests
IntegrationTests
DocumentationDocumentation
ValidationValidation
MaintenanceMaintenance
VerificationRequirements
Realiz
atio
n
Session 3.1 Cryogenic Storage Systems G. Bartlok 6
Risk Management
Safety Integrity Level (SIL)A fault of a specific component can lead to death of some people.
≥<
(EN ISO 13849-1 or IEC 61508-1)
Specific ComponentsL-H2 storage vessel and pipesSafety devices
1st shut-off valve (downstream)
Sensors
Safety related electronics
Risk analysisFailure Mode and Effect Analysis (FMEA)
Failure Tree Analysis (FTA)
Session 3.1 Cryogenic Storage Systems G. Bartlok 7
• Welding process
• WIG – automatic and manual welding of stainless steel parts
Manufacturing – Production
Source: MAGNA STEYR
Session 3.1 Cryogenic Storage Systems G. Bartlok 8
• Dye penetration inspection of valve housings and welding seams
Manufacturing – Quality Inspection
Source: MAGNA STEYRSource: MAGNA STEYR
Session 3.1 Cryogenic Storage Systems G. Bartlok 9
Hydrogen Quality Guideline SAE J2719• max. Particle size:
< 10 µm • Particulate concentration:
1 µg/liter
Source: MAGNA STEYR
• Cleaning of hydrogen containing pipes in the inner tank, vacuum chamber and auxiliary system box
• Cleaning process of inner tank shell and outer jacket shell in a washing machine
• Use of special cleaning solutions
Manufacturing – Cleaning Process
Session 3.1 Cryogenic Storage Systems G. Bartlok 10
Source: MAGNA STEYR
Assembly• Mechanical and electrical
installation of the liquid hydrogen level sensor in the inner tank
Manufacturing – Assembly
Session 3.1 Cryogenic Storage Systems G. Bartlok 11
Source: MAGNA STEYR
Multi-Layer Insulation• Installation of layers of high
reflecting aluminum foils and spacer of glass fiber in a clean-room
• Sewing process for fixing the foils and spacer on the inner tank
Manufacturing – Thermal Insulation
Source: MAGNA STEYR
Session 3.1 Cryogenic Storage Systems G. Bartlok 12
Vacuum and Getter• Evacuating the thermal insulation
space down to 10-2 Pa within a heating chamber by use of turbo-molecular pumps
• Activating the getter material
Manufacturing – Thermal Insulation
Source: MAGNA STEYR
Session 3.1 Cryogenic Storage Systems G. Bartlok 13
Leak test• Leak detection of components in
the auxiliary system box
Manufacturing – Quality Inspection
Source: MAGNA STEYR
Session 3.1 Cryogenic Storage Systems G. Bartlok 14
Source: MAGNA STEYR
Mechanical inspections• Visual inspections of joints
• Penetration and X-ray tests of welding seems
• Inner tank pressure test
• System tightness tests
• Positioning of interfaces
Electrical checks• Operation of sensors (p, T)
• Operation of valves
Manufacturing – End of Line
Session 3.1 Cryogenic Storage Systems G. Bartlok 15
Functional tests• Verification of valves and sensors
at operating conditions
• System leak-rate measurement
• Verification of refueling time
• Validation of autonomy time
• Validation of boil-off rate
• Validation of specified hydrogen extraction rates
Source: HyCentA
Manufacturing – Performance Test
Session 3.1 Cryogenic Storage Systems G. Bartlok 16
TRANS/WP.29/GRPE/2003/14/Add.1
Design Rules Design Rules –– Regulation & StandardsRegulation & Standards
Specific Components
- Container- Pipes- Manual and automatic valves- Refuelling connection or receptacle- Heat exchanger- Pressure regulator- Sensors
Validation tests
- Pressure cycling tests- Temperature cycling tests- Leakage tests- Hydrogen tests- Bonfire tests- Functional tests- Durability tests
Proposal for draft amendments to the new draft regulation onuniform provisions concerning the approval of:
I. Specific components of motor vehicles using L-H2
II. Vehicle with regard to the installation of specific components for the use of L-H2
Session 3.1 Cryogenic Storage Systems G. Bartlok 17
Vacuum loss test
Destructive Tests
Bonfire test
Proves the design of the pressure relief devices in case of a degraded thermal insulation
Following behaviours are observed:• tank pressure and temperatures• hydrogen blow-off behaviour• hydrogen blow-off time
The average temperature in the space 10 mm below the fuel tank shall be at least 863 K
Thermal autonomy of the liquid hydrogen fuel tank shall be at least5 minutes
Verification of the design of the pressure relief devices
Source: Energie Technologie Source: BAM
Session 3.1 Cryogenic Storage Systems G. Bartlok 18
Crash and skid test
Destructive Tests
Dynamic vibration test
Statistic values for estimating the lifetime behaviour
Inner tank:
• at ambient temperature
• at cryogenic temperature(filled with liquid hydrogen)
In order to examine the:
• connection between body and liquidhydrogen fuel tank
• the suspension of the inner tank athigh external loads
Source: BMW GroupSource: MAGNA STEYR
Session 3.1 Cryogenic Storage Systems G. Bartlok 19
2005 2010 2015 2020 20xx
≥≥50%50%
Deg
ree
of
Au
tom
atio
nD
egre
e o
f A
uto
mat
ion
~3%~3%Units per Units per
YearYear
1,00010010 100,00010,000
MassProduction
Prototypes
Co
sts
per
Tan
k
Factor10 to 50
Cost Reduction – Degree of Automation Degree of Automation vs. Costs (vs. Costs (Prospects)
Session 3.1 Cryogenic Storage Systems G. Bartlok 20
Prospects for Hydrogen Storage Systems
2010:50.000 units
2015:300.000. units
Price/quantity effects thanks to
number of units
(lightweight free form geometry)
Price/quantity effects thanks to
modular design strategy
(flat tank geometry)
on-board power supply
2004 20152010
3 Mio.
2020
1 Mio.
2 Mio.
Quantities are estimated2006 2008
prototypeflat storage tanks
price increase of gasoline
legal environmental requirements
160 kg gasoline tank equivalent 80 kg
200820062005
new materials + concepts
common lightweightconcepts and materials
Session 3.1 Cryogenic Storage Systems G. Bartlok 21
State of the artSeries BMW
Future System
NextSteps
• geometry / package • increase capacity• increase autonomy time• reduce and use boil-off losses• reduce system weight while using
new materials• increase road capability• reduce system costs
L-H2 Tanks – Next Steps
Session 3.1 Cryogenic Storage Systems G. Bartlok 22
0 till 0.70 till 0.7MPaOperating Pressure
> 1
2
2
- 253 till + 85
10
1.5
3.3
90
250
10
Future System
1
4
1.5
- 253 till + 85
5.3
1
1.7
160
295
9
State of the Art System
daysSystem Autonomy Time
%/dayBoil-off Rate
kg/minRefuelling Rate
°COperating Temperature
wt%Hydrogen Storage Capacity
kWh/lVolumetric Energy Density
kWh/kgGravimetric Energy Density
kgSystem Mass (without Hydrogen)
lSystem Volume (shrink wrap)
kgHydrogen Storage Mass
UnitParameter
Requirements and Goals
State of the Art
Future System
Session 3.1 Cryogenic Storage Systems G. Bartlok 23
Needs and Opportunities for Future R&D Activities
Requirement Approach of a Solution
Integration Complex Free-form Geometrie
Lightweight e.g. Composite Materials
Mass production Processes for High Volume Production
Costs Modular Design, Economic Processesand Materials
Development of an free-form lightweight tank system manufactured from e.g. CFRP as well as adequate production technologies
Session 3.1 Cryogenic Storage Systems G. Bartlok 24
• Industrialisation concepts for mass production capability, cost reduction, quality, e.g. applying transition strategies from non-hydrogen technologies (e.g. CNG storage) toward hydrogen
• System validation of newly developed storage systems• Integration into vehicle, including safety aspects, total thermal
management, etc.
• Interaction with fuelling stations, hydrogen infrastructure • Component development: e.g. filling devices, valves,
temperature and pressure sensors, active cooling, hydrogen gas detectors, safety-related electrics/electronics
• Probabilistic safety approach for design and approval -improvement of standards and regulations
Needs and Opportunities for Future R&D Activities
Session 3.1 Cryogenic Storage Systems G. Bartlok 25
• Evolving the hydrogen economy will take time, strong partners and financial commitment
• Acceptance of industry and public required
• There is an enormous potential for design improvements without a decrease of safety level
• The first series Hydrogen StorageSystem will be engineered and produced by MAGNA STEYR by 2007
Conclusions
Session 1.2: IntroductoryLectures
K. Hall
Session 3.1: Cryogenic Storage Systems
Dr. G. Bartlok
25th – 29th September 2006Ingolstadt
