Applications & Pathways

Hydrogen refueling stations rely on pressure vessels capable of withstanding pressures up to 90 MPa while mitigating concerns related to hydrogen embrittlement. However a gap exists in understanding the long-term fatigue behavior of these vessels under real operational conditions. This study focuses on evaluating the safety of SA372 pressure vessels using operational data from a hydrogen refueling station in Pyeongtaek South Korea. A predictive reinspection methodology is proposed based on this evaluation. Parameters including hydrogen-induced stress intensity factor (KIH) initial crack size (a0 c0) and pressure vessel specifications are considered to assess critical crack depth (ac) critical usage cycles (Nc) and allowable usage cycles (Nallowed). Leveraging operational data collected between August and November 2023 fatigue analysis and Rainflow counting inform reinspection schedules. Results indicate a need for mid-bank vessel reinspection within the second year high-bank vessel reinspection every 20 years and low-bank vessel reinspection every 143 years in accordance with safety regulations. Additionally a revised refueling logic is proposed to optimize vehicle charging methods and pressure ranges enhancing operational safety. This study serves as a preliminary investigation highlighting the need for broader data collection and analysis to generalize findings across multiple stations.

The Integrated Energy System (IES) that coordinates multiple energy sources can effectively improve energy utilization and is of great significance to achieving energy conservation and emission reduction goals. In this context a low-carbon and economic dispatch model for IES is proposed. Firstly a hydrogen energy-based IES (H2-IES) is constructed to refine the utilization process of hydrogen energy. Secondly the carbon emissions of different energy chains throughout their life cycle are analyzed using the life cycle assessment method (LCA) and the carbon emissions of the entire energy supply and demand chain are considered. Finally a staged carbon trading mechanism is adopted to promote energy conservation and emission reduction. Based on this an IES low-carbon and economic dispatch model is constructed with the optimization goal of minimizing the sum of carbon trading costs energy procurement costs and hydrogen sales revenue while considering network constraints and constraints on key equipment. By analyzing the model under different scenarios the introduction of life cycle assessment staged carbon trading and hydrogen energy utilization is shown to promote low-carbon and economic development of the comprehensive energy system.

Sustainable aviation fuel (SAF) production is one of the strategies to guarantee an environmental-friendly development of the aviation sector. This work evaluates the technical economic and environmental feasibility of obtaining SAFs by hydrogenation of vegetable oils thanks to in-situ hydrogen production via aqueous phase reforming (APR) of glycerol by-product. The novel implementation of APR would avoid the environmental burden of conventional fossil-derived hydrogen production as well as intermittency and storage issues related to the use of RES-based (renewable energy sources) electrolysers. The conceptual design of a conventional and advanced (APR-aided) biorefinery was performed considering a standard plant capacity equal to 180 ktonne/y of palm oil. For the advanced scenario the feed underwent hydrolysis into glycerol and fatty acids; hence the former was subjected to APR to provide hydrogen which was further used in the hydrotreatment reactor where the fatty acids were deoxygenated. The techno-economic results showed that APR implementation led to a slight increase of the fixed capital investment by 6.6% compared to the conventional one while direct manufacturing costs decreased by 22%. In order to get a 10% internal rate of return the minimum fuel selling price was found equal to 1.84 $/kg which is 17% lower than the one derived from conventional configurations (2.20 $/kg). The life-cycle GHG emission assessment showed that the carbon footprint of the advanced scenario was equal to ca. 12 g CO2/MJSAF i.e. 54% lower than the conventional one (considering an energy-based allocation). The sensitivity analysis pointed out that the cost of the feedstock SAF yield and the chosen plant size are keys parameters for the marketability of this biorefinery while the energy price has a negligible impact; moreover the source of hydrogen has significant consequences on the environmental footprint of the plant. Finally possible uncertainties for both scenarios were undertaken via Monte Carlo simulations.

In the framework of the ongoing EMPIR JRP 16ENG01 ‘‘Metrology for Hydrogen Vehicles’’ a main task is to investigate the influence of pressure on the measurement accuracy of Coriolis Mass Flow Meters (CFM) used at Hydrogen Refueling Stations (HRS). At a HRS hydrogen is transferred at very high and changing pressures with simultaneously varying flow rates and temperatures. It is clearly very difficult for CFMs to achieve the current legal requirements with respect to mass flow measurement accuracy at these measurement conditions. As a result of the very dynamic filling process it was observed that the accuracy of mass flow measurement at different pressure ranges is not sufficient. At higher pressures it was found that particularly short refueling times cause significant measurement deviations. On this background it may be concluded that pressure has a great impact on the accuracy of mass flow measurement. To gain a deeper understanding of this matter RISE has built a unique high-pressure test facility. With the aid of this newly developed test rig it is possible to calibrate CFMs over a wide pressure and flow range with water or base oils as test medium. The test rig allows calibration measurements under the conditions prevailing at a 70 MPa HRS regarding mass flows (up to 3.6 kg min−1) and pressures (up to 87.5 MPa).

In this work the design and modeling of a fuel cell vehicle using low-loading platinum catalysts were investigated. Data from single fuel cells with low Pt-loading cathode catalysts were scaled up to fuel cell stacks and systems implemented in a vehicle and then compared to a commercial fuel cell vehicle. The low-loading Pt systems have shown lower efficiency at high loads compared to the commercial systems suggesting less stable materials. However the analysis showed that the vehicle comprising low-loading Pt catalysts achieves similar or higher efficiency compared to the commercial fuel cell vehicle when being scaled up for the same number of cells. When the systems were scaled up for the same maximum power as the commercial fuel cell vehicle all the low-loading Pt fuel cell systems showed higher efficiencies. In this case more cells are needed but still the amount of Pt is significantly reduced compared to the commercial one. The high-efficiency results can be associated with the vehicle’s power range operation that meets the region where the low-loading Pt fuel cells have high performance. The results suggested a positive direction towards the reduction of Pt in commercial fuel cell vehicles supporting a cost-competitive clean energy transition based on hydrogen.

Recently major problems related to fuel consumption and greenhouse gas (GHG) emissions have arisen in the transportation sector. Therefore developing transportation modes powered by alternative fuels has become one of the main targets for car manufacturers and governments around the world. This study aimed to investigate the economic prospects of using hydrogen fuel cell technology in taxi fleets in Westbank. For this purpose a model that could predict the number of taxis was developed and the expected economic implications of using hydrogen fuel cell technology in taxi fleets were determined based on the expected future fuel consumption and future fuel cost. After analysis of the results it was concluded that a slight annual increase in the number of taxis in Palestine is expected in the future due to the government restrictions on issuing new taxi permits in order to get this sector organized. Furthermore using hydrogen fuel cells in taxi fleets is expected to become more and more feasible over time due to the expected future increase in oil price and the expected significant reduction in hydrogen cost as a result of the new technologies that are expected to be used in the production and handling of hydrogen.

Blending hydrogen to existing fuel mix represents a major opportunity for decarbonisation. One important consideration for this application is the chemical interaction between hydrogen and hydrocarbon fuels arising from their different combustion chemistries and varying considerably with combustion processes. This paper conducted an exploratory study of hydrogen’s impact on autoignition in several combustion processes where hydrogen is used as a blending component or the main fuel. Case studies are presented for spark ignition engines (H2/natural gas) compression ignition engines (H2/diesel) moderate or intense low-oxygen dilution (MILD) combustors (H2/natural gas) and rotational detonation engines (H2/natural gas). Autoignition reactivity as a function of the hydrogen blending level is investigated numerically using the ignition delay iso-contours and state-of-the-art kinetic models at time scales representative of each application. The results revealed drastically different impact of hydrogen blending on autoignition due to different reaction temperature pressure and time scale involved in these applications leaving hydrocarbon interacting with hydrogen at different ignition branches where the negative pressure/temperature dependency of oxidation kinetics could take place. The resulted non-linear and at times non-monotonic behaviours indicate a rich topic for combustion chemistry and also demonstrates ignition delay iso-contour as a useful tool to scope autoignition reactivity for a wide range of applications.

Distributed waste-to-hydrogen (WtH) systems are a potential solution to tackle the dual challenges of sustainable waste management and zero emission transport. Here we propose a concept of distributed WtH systems based on gasification and fermentation to support hydrogen fuel cell buses in Glasgow. A variety of WtH scenarios were configured based on biomass waste feedstock hydrogen production reactors and upstream and downstream system components. A cost-benefit analysis (CBA) was conducted to compare the economic feasibility of the different WtH systems with that of the conventional steam methane reforming-based method. This required the curation of a database that included inter alia direct cost data on construction maintenance operations infrastructure and storage along with indirect cost data comprising environmental impacts and externalities cost of pollution carbon taxes and subsidies. The levelized cost of hydrogen (LCoH) was calculated to be 2.22 GB P/kg for municipal solid waste gasification and 2.02 GB P/kg for waste wood gasification. The LCoHs for dark fermentation and combined dark and photo fermentation systems were calculated to be 2.15 GB P/kg and 2.29 GB P/kg. Sensitivity analysis was conducted to identify the most significant influential factors of distributed WtH systems. It was indicated that hydrogen production rates and CAPEX had the largest impact for the biochemical and thermochemical technologies respectively. Limitations including high capital expenditure will require cost reduction through technical advancements and carbon tax on conventional hydrogen production methods to improve the outlook for WtH development.

This paper aims to optimize dual-fuel facilitated off-/on-grid multi-energy systems (MESs) for different renewable energy zones (REZs) in Australia. The main objective is to develop a novel MES with the main feature of green hydrogen production and blended natural gas utilization for remote households. The proposed optimal system produces green hydrogen of 5343 kg/yr via proton exchange membrane (PEM) electrolyzer and blends it with natural gas. It involves 20 % hydrogen and 80 % natural gas in the overall volume of the blending process. This study contributes by performing optimal sizing of the components economic-energy-environmental and performance analyses to examine the most feasible solution for each REZ. The results indicate that the optimal system in North Queensland REZ has the lowest levelized cost of energy (LCE) of 1.28 A$/kWh and 0.1003 A $/kWh and the net present cost (NPC) of A$0.311 million and A$0.219 million for off-grid and on-grid configurations. The optimal on-grid system has 95.27 % less carbon emissions than the natural gas-fueled combustion energy system.

The depletion of fossil fuel sources has encouraged the authorities to use renewable resources such as wind energy to generate electricity. A backup/storage system can improve the performance of wind turbines due to fluctuations in power demand. The novelty of this study is to utilize a hybrid system for a wind farm using the excess electricity generated by the wind turbines to produce hydrogen in an alkaline electrolyzer (AEL). The hydrogen storage tank stores the produced hydrogen and provides hydrogen to the proton-exchange membrane fuel cell (PEMFC) to generate electricity once the power demand is higher than the electricity generated by the wind turbines. The goal of this study is to use the wind profile of a region in Iran namely the Cohen region to analyze the performance of the suggested integrated system on a micro scale. The output results of this study can be used as a case study for construction in the future based on the exact specification of NTK300 wind turbines. The results indicate that with the minimum power supply of 30 kW from the wind turbines on a lab scale the generated power by the PEMFC will be 1008 W while the maximum generated hydrogen will be 304 mL/h.