Germany

Climate and energy policies are tools used to steer the development of a sustainable economy supplied by equally sustainable energy systems. End-users should plan their investments accounting for future policies such as incentives for system-oriented consumption emission prices and hydrogen economy to ensure long-term competitiveness. In this work the utilization of variable renewable energy and flexibility potentials in a case study of an an aggregate industry is investigated. An energy concept considering PV and battery expansion flexible production fuel cell electric trucks (FCEV) and hydrogen production is proposed and analysed under expected techno-economic conditions and policies of 2030 using an energy system optimization model. Under this concept total costs and emissions are reduced by 14% and 70% respectively compared to the business-as-usual system. The main benefit of PV investment is the lowered electricity procurement. Flexibility from schedule manufacturing and hydrogen production increases not only the self-consumption of PV generation from 51% to 80% but also the optimal PV capacity by 41%. Despite the expected cost reduction and efficiency improvement FCEV is still not competitive to diesel trucks due to higher investment and fuel prices i.e. its adoption increases the costs by 8%. However this is resolved when hydrogen can be produced from own surplus electricity generation. Our findings reveal synergistic effects between different potentials and the importance of enabling local business models e.g. regional hydrogen production and storage services. The SWOT analysis of the proposed concept shows that the pursuit of sustainability via new technologies entails new opportunities and risks. Lastly end-users and policymakers are advised to plan their investments and supports towards integration of multiple application consumption sectors and infrastructure.

Germany’s energy transition known as ‘Energiewende’ was always very progressive. However it came technically to a halt at the question of large-scale seasonal energy storage for wind and solar which was not available. At the end of the 2000s we combined our knowledge of both electrical and process engineering imitated nature by copying photosynthesis and developed Power-to-Gas by combining water electrolysis with CO2 -methanation to convert water and CO2 together with wind and solar power to synthetic natural gas. Storing green energy by coupling the electricity with the gas sector using its vast TWh-scale storage facility was the solution for the biggest energy problem of our time. This was the first concept that created the term ‘sector coupling’ or ‘sectoral integration’. We first implemented demo sites presented our work in research industry and ministries and applied it in many macroeconomic studies. It was an initial idea that inspired others to rethink electricity as well as eFuels as an energy source and energy carrier. We developed the concept further to include Power-to-Liquid Power-to-Chemicals and other ways to ‘convert’ electricity into molecules and climate-neutral feedstocks and named it ‘Power-to-X’ at the beginning of the 2010s.

Since the 1970s hydrogen has been considered as a possible energy carrier for the storage of renewable energy. The main focus has been on addressing the ultimate challenge: developing an environmentally friendly successor for gasoline. This very ambitious goal has not yet been fully reached as discussed in this review but a range of new lightweight hydrogen-containing materials has been discovered with fascinating properties. State-of-the-art and future perspectives for hydrogen-containing solids will be discussed with a focus on metal borohydrides which reveal significant structural flexibility and may have a range of new interesting properties combined with very high hydrogen densities.

Tensile and fatigue tests were performed on an AA2198 aluminum alloy in the T851 condition in ambient air and liquid hydrogen (LH2). All fatigue tests were performed under load control at a frequency of 20 Hz and a stress ratio of R=0.1. The Gecks-Och-Function [1] was fitted on the measured cyclic lifetimes.<br/><br/>The tensile strength in LH2 was measured to be 46 % higher compared to the value determined at ambient conditions and the fatigue limit was increased by approximately 60 %. Both S-N curves show a distinct S-shape but also significant differences. Under LH2 environment the transition from LCF- to HCF-region as well as the transition to the fatigue limit is shifted to higher cyclic lifetimes compared to ambient test results. The investigation of the crack surfaces showed distinct differences between ambient and LH2 conditions. These observed differences are important factors in the fatigue behavior change.

The ultrafine-grained (UFG) duplex microstructure of medium-Mn steel consists of a considerable amount of austenite and ferrite/martensite achieving an extraordinary balance of mechanical properties and alloying cost. In the present work two heat treatment routes were performed on a cold-rolled medium-Mn steel Fe-12Mn-3Al-0.05C (wt.%) to achieve comparable mechanical properties with different microstructural morphologies. One heat treatment was merely austenite-reverted-transformation (ART) annealing and the other one was a successive combination of austenitization (AUS) and ART annealing. The distinct responses to hydrogen ingression were characterized and discussed. The UFG martensite colonies produced by the AUS + ART process were found to be detrimental to ductility regardless of the amount of hydrogen which is likely attributed to the reduced lattice bonding strength according to the H-enhanced decohesion (HEDE) mechanism. With an increase in the hydrogen amount the mixed microstructure (granular + lamellar) in the ART specimen revealed a clear embrittlement transition with the possible contribution of HEDE and H-enhanced localized plasticity (HELP) mechanisms.

Our contribution demonstrates that hydrogen storage in stationary Liquid Organic Hydrogen Carrier (LOHC) systems becomes much simpler and significantly more efficient if both the LOHC hydrogenation and the LOHC dehydrogenation reaction are carried out in the same reactor using the same catalyst. The finding that the typical dehydrogenation catalyst for hydrogen release from perhydro dibenzyltoluene (H18-DBT) Pt on alumina turns into a highly active and very selective dibenzyltoluene hydrogenation catalyst at temperatures above 220 °C paves the way for our new hydrogen storage concept. Herein hydrogenation of H0-DBT and dehydrogenation of H18-DBT is carried out at the same elevated temperature between 290 and 310 °C with hydrogen pressure being the only variable for shifting the equilibrium between hydrogen loading and release. We demonstrate that the heat of hydrogenation can be provided at a temperature level suitable for effective dehydrogenation catalysis. Combined with a heat storage device of appropriate capacity or a high pressure steam system this heat could be used for dehydrogenation.

Carbon capture and storage (CCS) is broadly recognised as having the potential to play a key role in meeting climate change targets delivering low carbon heat and power decarbonising industry and more recently its ability to facilitate the net removal of CO₂ from the atmosphere. However despite this broad consensus and its technical maturity CCS has not yet been deployed on a scale commensurate with the ambitions articulated a decade ago. Thus in this paper we review the current state-of-the-art of CO₂ capture transport utilisation and storage from a multi-scale perspective moving from the global to molecular scales. In light of the COP21 commitments to limit warming to less than 2 °C we extend the remit of this study to include the key negative emissions technologies (NETs) of bioenergy with CCS (BECCS) and direct air capture (DAC). Cognisant of the non-technical barriers to deploying CCS we reflect on recent experience from the UK's CCS commercialisation programme and consider the commercial and political barriers to the large-scale deployment of CCS. In all areas we focus on identifying and clearly articulating the key research challenges that could usefully be addressed in the coming decade.

The chemical and petrochemical sector relies on fossil fuels and feedstocks and is a major source of carbon dioxide (CO2 ) emissions. The techno-economic potential of 20 decarbonisation options is assessed. While previous analyses focus on the production processes this analysis covers the full product life cycle CO2 emissions. The analysis elaborates the carbon accounting complexity that results from the non-energy use of fossil fuels and highlights the importance of strategies that consider the carbon stored in synthetic organic products—an aspect that warrants more attention in long-term energy scenarios and strategies. Average mitigation costs in the sector would amount to 64 United States dollars (USD) per tonne of CO2 for full decarbonisation in 2050. The rapidly declining renewables cost is one main cause for this low-cost estimate. Renewable energy supply solutions in combination with electrification account for 40% of total emissions reductions. Annual biomass use grows to 1.3 gigatonnes; green hydrogen electrolyser capacity grows to 2435 gigawatts and recycling rates increase six-fold while product demand is reduced by a third compared to the reference case. CO2 capture storage and use equals 30% of the total decarbonisation effort (1.49 gigatonnes per year) where about one-third of the captured CO2 is of biogenic origin. Circular economy concepts including recycling account for 16% while energy efficiency accounts for 12% of the decarbonisation needed. Achieving full decarbonisation in this sector will increase energy and feedstock costs by more than 35%. The analysis shows the importance of renewables-based solutions accounting for more than half of the total emissions reduction potential which was higher than previous estimates.

In the near future the challenges to reduce the economic and social dependency on fossil fuels must be faced increasingly. A sustainable and efficient energy supply based on renewable energies enables large-scale applications of electro-fuels for e.g. the transport sector. The high gravimetric energy density makes liquefied hydrogen a reasonable candidate for energy storage in a light-weight application such as aviation. Current aircraft structures are designed to accommodate jet fuel and gas turbines allowing a limited retrofitting only. New designs such as the blended-wing-body enable a more flexible integration of new storage technologies and energy converters e.g. cryogenic hydrogen tanks and fuel cells. Against this background a tank-design model is formulated which considers geometrical mechanical and thermal aspects as well as specific mission profiles while considering a power supply by a fuel cell. This design approach enables the determination of required tank mass and storage density respectively. A new evaluation value is defined including the vented hydrogen mass throughout the flight enabling more transparent insights on mass shares. Subsequently a systematic approach in tank partitioning leads to associated compromises regarding the tank weight. The analysis shows that cryogenic hydrogen tanks are highly competitive with kerosene tanks in terms of overall mass which is further improved by the use of a fuel cell.

Underground hydrogen storage is a potential way to balance seasonal fluctuations in energy production from renewable energies. The risks of hydrogen storage in depleted gas fields include the conversion of hydrogen to CH4(g) and H2S(g) due to microbial activity gas–water–rock interactions in the reservoir and cap rock which are connected with porosity changes and the loss of aqueous hydrogen by diffusion through the cap rock brine. These risks lead to loss of hydrogen and thus to a loss of energy. A hydrogeochemical modeling approach is developed to analyze these risks and to understand the basic hydrogeochemical mechanisms of hydrogen storage over storage times at the reservoir scale. The one-dimensional diffusive mass transport model is based on equilibrium reactions for gas–water–rock interactions and kinetic reactions for sulfate reduction and methanogenesis. The modeling code is PHREEQC (pH-REdox-EQuilibrium written in the C programming language). The parameters that influence the hydrogen loss are identified. Crucial parameters are the amount of available electron acceptors the storage time and the kinetic rate constants. Hydrogen storage causes a slight decrease in porosity of the reservoir rock. Loss of aqueous hydrogen by diffusion is minimal. A wide range of conditions for optimized hydrogen storage in depleted gas fields is identified.

The article presents the methodology and applicable data for the generation of life cycle inventory for conventional and alternative processes for base chemical production by process simulation. Addressed base chemicals include lower olefins BTX aromatics methanol ammonia and hydrogen. Assessed processes include conventional chemical production processes from naphtha LPG natural gas and heavy fuel oil; feedstock recycling technologies via gasification and pyrolysis of refuse derived fuel; and power-to-X technologies from hydrogen and CO2. Further process variations with additional hydrogen input are covered. Flowsheet simulation in Aspen Plus is applied to generate datasets with conclusive mass and energy balance under uniform modelling and assessment conditions with available validation data. Process inventory data is generated with no regard to the development stage of the respective technology but applicable process data with high technology maturity is prioritized for model validation. The generated inventory data can be applied for life cycle assessments. Further the presented modelling and balancing framework can be applied for inventory data generation of similar processes to ensure comparability in life cycle inventory data.

Electrifying energy-intensive processes is currently intensively explored to cut greenhouse gas (GHG) emissions through renewable electricity. Electrification is particularly challenging if fossil resources are not only used for energy supply but also as feedstock. Copper production is such an energy-intensive process consuming large quantities of fossil fuels both as reducing agent and as energy supply.

Here we explore the techno-economic potential of Power-to-Hydrogen to decarbonize copper production. To determine the minimal cost of an on-site retrofit with Power-to-Hydrogen technology we formulate and solve a mixed-integer linear program for the integrated system. Under current techno-economic parameters for Germany the resulting direct CO₂ abatement cost is 201 EUR/t CO₂-eq for Power-to-Hydrogen in copper production. On-site utilization of the electrolysis by-product oxygen has a substantial economic benefit. While the abatement cost vastly exceeds current European emission certificate prices a sensitivity analysis shows that projected future developments in Power-to-Hydrogen technologies can greatly reduce the direct CO₂ abatement cost to 54 EUR/t CO₂-eq. An analysis of the total GHG emissions shows that decarbonization through Power-to-Hydrogen reduces the global GHG emissions only if the emission factor of the electricity supply lies below 160 g CO2-eq/kWhel.

The results suggest that decarbonization of copper production by Power-to-Hydrogen could become economically and environmentally beneficial over the next decades due to cheaper and more efficient Power-to-Hydrogen technology rising GHG emission certificate prices and further decarbonization of the electricity supply.

The H₂ internal combustion engine (ICE) is a key technology for complete decarbonization of the transport sector. To match or exceed the power density of conventional combustion engines H₂ direct injection (DI) is essential. Therefore new injector concepts that meet the requirements of a H₂ operation have to be developed. The macroscopic free stream behavior of H2 released from an innovative fluidic oscillating nozzle is investigated and compared with that of a conventional multi-hole nozzle. This work consists of H₂ flow measurements and injection tests in a constant volume chamber using the Schlieren method and is accompanied by a LES simulation. The results show that an oscillating H₂ free stream has a higher penetration velocity than the individual jets of a multi-hole nozzle. This behavior can be used to inject H₂ far into the combustion chamber in the vertical direction while the piston is still near bottom dead center. As soon as the oscillation of the H₂ free stream starts the spray angle increases and therefore H2 is also distributed in the horizontal direction. In this phase of the injection process spray angles comparable to those of a multi-hole nozzle are achieved. This behavior has a positive effect on H2 homogenization which is desirable for the combustion process.

In this paper the implications of the use of hydrogen on product yield and conversion efficiency as well as on economic performance of a hydrogen enhanced Biomass-to-Liquid (BtL) process are analyzed. A process concept for the synthesis of fuel (gasoline and LPG) from biomass-derived synthesis gas via Methanol-to-Gasoline (MtG) route with utilization of carbon dioxide from gasification by feeding additional hydrogen is developed and modeled in Aspen Plus. The modeled process produces 0.36 kg fuel per kg dry straw. Additionally 99 MW electrical power are recovered from purge and off gases from fuel synthesis in CCGT process covering the electricity consumption of fuel synthesis and synthesis gas generation. The hydrogen enhanced BtL procces reaches a combined chemical and electrical efficiency of 48.2% and overall carbon efficiency of 69.5%. The total product costs (TPC) sum up to 3.24 €/kg fuel. Raw materials (hydrogen and straw) make up the largest fraction of TPC with a total share of 75%. The hydrogen enhanced BtL process shows increased chemical energy and carbon efficiencies and thus higher product yields. However economic analysis shows that the process is unprofitable under current conditions due to high costs for hydrogen provision.

Using electricity for heating can contribute to decarbonization and provide flexibility to integrate variable renewable energy. We analyze the case of electric storage heaters in German 2030 scenarios with an open-source electricity sector model. We find that flexible electric heaters generally increase the use of generation technologies with low variable costs which are not necessarily renewables. Yet making customary night-time storage heaters temporally more flexible offers only moderate benefits because renewable availability during daytime is limited in the heating season. Respective investment costs accordingly have to be very low in order to realize total system cost benefits. As storage heaters feature only short-term heat storage they also cannot reconcile the seasonal mismatch of heat demand in winter and high renewable availability in summer. Future research should evaluate the benefits of longer-term heat storage.

This paper analyses some possible means by which renewable power could be integrated into the steel manufacturing process with techniques such as blast furnace gas recirculation (BF-GR) furnaces that utilize carbon capture a higher share of electrical arc furnaces (EAFs) and the use of direct reduced iron with hydrogen as reduction agent (H-DR). It is demonstrated that these processes could lead to less dependence on—and ultimately complete independence from—coal. This opens the possibility of providing the steel industry with power and heat by coupling to renewable power generation (sector coupling). In this context it is shown using the example of Germany that with these technologies reductions of 47–95% of CO2 emissions against 1990 levels and 27–95% of primary energy demand against 2008 can be achieved through the integration of 12–274 TWh of renewable electrical power into the steel industry. Thereby a substantial contribution to reducing CO2 emissions and fuel demand could be made (although it would fall short of realizing the German government’s target of a 50% reduction in power consumption by 2050).

Achieving climate-neutrality requires considerable investment in energy storage systems (ESS) to integrate variable renewable energy sources into the grid. However investments into ESS are often unprofitable in particular for grid-scale battery storage and green hydrogen technologies prompting many actors to call for policy intervention. This study investigates investor-specific risk-return preferences for ESS investment and derives policy recommendations. Insights are drawn from 1605 experimental investment-related decisions obtained from 42 high-level institutional investors and utility representatives. Results reveal that both investor groups view revenue stacking as key to making ESS investment viable. While the expected return on investment is the most important project characteristic risk-return preferences for other features diverge between groups. Institutional investors appear more open to exploring new technological ventures (20% of utility respondents would not consider making investments into solar photovoltaic-hydrogen) whereas utilities seem to prefer greenfield projects (23% of surveyed institutional investors rejected such projects). Interestingly both groups show strong aversion towards energy market price risk. Institutional investors require a premium of 6.87 percentage points and utilities 5.54 percentage points for moving from a position of fully hedged against market price risk to a scenario where only 20% of revenue is fixed underlining the need for policy support.

Iron aluminides have been among the most studied intermetallics since the 1930s when their excellent oxidation resistance was first noticed. Their low cost of production low density high strength-to-weight ratios good wear resistance ease of fabrication and resistance to high temperature oxidation and sulfurization make them very attractive as a substitute for routine stainless steel in industrial applications. Furthermore iron aluminides allow for the conservation of less accessible and expensive elements such as nickel and molybdenum. These advantages have led to the consideration of many applications such as brake disks for windmills and trucks filtration systems in refineries and fossil power plants transfer rolls for hot-rolled steel strips and ethylene crackers and air deflectors for burning high-sulfur coal. A wide application for iron aluminides in industry strictly depends on the fundamental understanding of the influence of (i) alloy composition; (ii) microstructure; and (iii) number (type) of defects on the thermo-mechanical properties. Additionally environmental degradation of the alloys consisting of hydrogen embrittlement anodic or cathodic dissolution localized corrosion and oxidation resistance in different environments should be well known. Recently some progress in the development of new micro- and nano-mechanical testing methods in addition to the fabrication techniques of micro- and nano-scaled samples has enabled scientists to resolve more clearly the effects of alloying elements environmental items and crystal structure on the deformation behavior of alloys. In this paper we will review the extensive work which has been done during the last decades to address each of the points mentioned above.

Greenhouse gas emissions need to be drastically reduced to mitigate the environmental impacts caused by climate change and to lead to a transformation of the European energy system. A model landscape consisting of four final energy consumption sector models with high spatial (NUTS-3) and temporal (hourly) resolution and the multi-energy system model ISAaR is extended and applied to investigate the transformation pathway of the European energy sector in the deep emission mitigation scenario solidEU. The solidEU scenario describes not only the techno-economic but also the socio-political contexts and it includes the EU27 + UK Norway and Switzerland. The scenario analysis shows that volatile renewable energy sources (vRES) dominate the energy system in 2050. In addition the share of flexible sector coupling technologies increases to balance electricity generation from vRES. Seasonal differences are balanced by hydrogen storage with a seasonal storage profile. The deployment rates of vRES in solidEU show that a fast profound energy transition is necessary to achieve European climate protection goals.

As 2018 marks the ten-year anniversary of the Fuel Cells and Hydrogen Joint Undertaking (FCH JU) it is inspiring to look back over the many accomplishments of the past decade. The projects described in these pages illustrate the approach of continuous learning exemplified by the FCH JU’s projects from creating low-carbon and sustainable solutions enabling market entry for new products developing ‘next generation’ products based on previous research to opening new markets for European expertise in fuel cell and hydrogen (FCH) technology.<br/>The FCH JU’s achievements are due in part to its multi-stakeholder structure: a public-private partnership between industry research and the European Commission. Industry-led research has pioneered new developments in FCH technology and brought many of them to the cusp of commercialisation. Market uptake from public authorities major companies and citizens alike has boosted confidence in these clean technologies establishing hydrogen as a cornerstone of Europe’s energy transition.<br/>DEVELOPING SOLUTIONS FOR A GREENER WORLD<br/>Citizens are at the heart of Europe’s Energy Union a strategy aimed at providing clean secure and affordable energy for all. For some years now and as a signatory to the Paris Agreement in 2015 the EU has been actively targeting reductions in carbon dioxide (CO2) emissions.

Green hydrogen produced by power‐to‐gas will play a major role in the defossilization of the energy system as it offers both carbon‐neutral chemical energy and the chance to provide flexibility. This paper provides an extensive analysis of hydrogen production in decentralized energy systems as well as possible operation modes (H2 generation or system flexibility). Modelling was realized for municipalities—the lowest administrative unit in Germany thus providing high spatial resolution—in the linear optimization framework OEMOF. The results allowed for a detailed regional analysis of the specific operating modes and were analyzed using full‐load hours share of used negative residual load installed capacity and levelized cost of hydrogen to derive the operation mode of power‐to‐gas to produce hydrogen. The results show that power‐to‐gas is mainly characterized by constant hydrogen production and rarely provides flexibility to the system. Main drivers of this dominant operation mode include future demand for hydrogen and the fact that high full‐load hours reduce hydrogen‐production costs. However changes in the regulatory market and technical framework could promote more flexibility and support possible use cases for the central technology to succeed in the energy transition.

A systematic study of different ratios of CO CO₂ N₂ gas components on the hydrogen storage properties of the Na₃AlH₆ complex hydride with 4 mol% TiCl3 8 mol% aluminum and 8 mol% activated carbon is presented in this paper. The different concentrations of CO and CO₂in H₂ and CO CO₂ N₂ in H₂ mixture were investigated. Both CO and CO₂gas react with the complex hydride forming Al oxy-compounds NaOH and Na₂CO₃ that consequently cause serious decline in hydrogen storage capacity. These reactions lead to irreversible damage of complex hydride under the current experimental condition. Thus after 10 cycles with 0.1 vol % CO + 99.9 vol %H₂ and 1 vol % CO + 99 vol %H₂ the dehydrogenation storage capacity of the composite material decreased by 17.2% and 57.3% respectively. In the case of investigation of 10 cycles with 1 vol % CO₂ + 99 vol % H₂ gas mixture the capacity degradation was 53.5%. After 2 cycles with 10 vol % CO +90 vol % H₂  full degradation was observed whereas after 6 cycles with 10 vol % CO₂+ 90 vol % H₂ degradation of 86.8% was measured. While testing with the gas mixture of 1.5 vol % CO + 10 vol % CO₂+ 27 vol % H₂ + 61.5 vol % N2 the degradation of 94% after 6 cycles was shown. According to these results it must be concluded that complex aluminum hydrides cannot be used for the absorption of hydrogen from syngas mixtures without thorough purification.

Hydrogen as carbon-free fuel is a very promising candidate for climate-neutral internal combustion engine operation. In comparison to other renewable fuels hydrogen does obviously not produce CO2 emissions. In this work two concepts of hydrogen internal combustion engines (H2 -ICEs) are investigated experimentally. One approach is the modification of a state-of-the-art gasoline passenger car engine using hydrogen direct injection. It targets gasoline-like specific power output by mixture enrichment down to stoichiometric operation. Another approach is to use a heavy-duty diesel engine equipped with spark ignition and hydrogen port fuel injection. Here a diesel-like indicated efficiency is targeted through constant lean-burn operation. The measurement results show that both approaches are applicable. For the gasoline engine-based concept stoichio-metric operation requires a three-way catalyst or a three-way NOX storage catalyst as the primary exhaust gas aftertreatment system. For the diesel engine-based concept state-of-the-art selective catalytic reduction (SCR) catalysts can be used to reduce the NOx emissions provided the engine calibration ensures sufficient exhaust gas temperature levels. In conclusion while H2 -ICEs present new challenges for the development of the exhaust gas aftertreatment systems they are capable to realize zero-impact tailpipe emission operation.

The paper presents the first outcomes of the experimental numerical and theoretical studies performed in the funded by Fuel Cell and Hydrogen Joint Undertaking (FCH2 JU) project HyTunnel-CS. The project aims to conduct pre-normative research (PNR) to close relevant knowledge gaps and technological bottlenecks in the provision of safety of hydrogen vehicles in underground transportation systems. Pre normative research performed in the project will ultimately result in three main outputs: harmonised recommendations on response to hydrogen accidents recommendations for inherently safer use of hydrogen vehicles in underground traffic systems and recommendations for RCS. The overall concept behind this project is to use inter-disciplinary and inter-sectoral prenormative research by bringing together theoretical modelling and experimental studies to maximise the impact. The originality of the overall project concept is the consideration of hydrogen vehicle and underground traffic structure as a single system with integrated safety approach. The project strives to develop and offer safety strategies reducing or completely excluding hydrogen-specific risks to drivers passengers public and first responders in case of hydrogen vehicle accidents within the currently available infrastructure.

The development of safe dispensing equipment for the fueling of heavy duty (HD) vehicles is critical to the expansion of this newly and quickly expanding market. This paper discusses the development of a HD dispenser and nozzles assembly (nozzle hose breakaway) for these new larger vehicles where flow rates are more than double compared to light duty (LD) vehicles. This equipment must operate at nominal pressures of 700 bar -40o C gas temperature and average flow rate of 5-10 kg/min at a high throughput commercial hydrogen fueling station without leaking hydrogen. The project surveyed HD vehicle manufacturers station developers and component suppliers to determine the basic specifications of the dispensing equipment and nozzle assembly. The team also examined existing codes and standards to determine necessary changes to accommodate HD components. From this information the team developed a set of specifications which will be used to design the dispensing equipment. In order to meet these goals the team performed computational fluid dynamic pressure modelling and temperature analysis in order to determine the necessary parameters to meet existing safety standards modified for HD fueling. The team also considered user operational and maintenance requirements such as freeze lock which has been an issue which prevents the removal of the nozzle from LD vehicles. The team also performed a failure mode and effects analysis (FMEA) to identify the possible failures in the design. The dispenser and nozzle assembly will be tested separately and then installed on an innovative HD fueling station which will use a HD vehicle simulator to test the entire system.