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California Hydrogen Research Consortium

Sam Sprik, Bill Buttner, Genevieve Saur, Mike Peters, Shaun Onorato, Mariya Koleva National Renewable Energy Laboratory DOE Project Award # 8.6.2.1 June 7 11, 2021

DOE Hydrogen Program 2021 Annual Merit Review and Peer Evaluation Meeting

Project ID # h2041

This presentation does not contain any proprietary, confidential, or otherwise restricted information

Project Goal

• California’s advanced hydrogen infrastructure is not duplicated anywhere in the United States and is unique in the world for its focus on providing a retail fueling experience.

• The combination of CA agencies and national labs in a consortium assists California in decisions, evaluations, and to verify solutions to problems impacting the industry.

• Projects in the consortium provide:

– Valuable data and analysis

– Verification of component solutions

– Experimental results for future hydrogen infrastructure

– Availability of technical experts to address issues in infrastructure development, deployment, operation, and technology advances

10/2018 – 3/2021 Objective: Conduct Research in 6 Separate Tasks NREL | 2

Overview

Timeline and Budget

• Project start date: 10/25/2018

• Project end date: – 7/31/2022 for Hydrogen Contaminant

Detector Project Task.

– 3/30/2021 for the other project tasks.

• Total project budget: $840k

– Total recipient share: $300k

– Total federal share: $540k

– Total DOE funds spent: $540k

Barriers • Reliability and Costs of Hydrogen

Compression (Delivery B)

• Other Fueling Site/Terminal Operations (Delivery I)

• Hydrogen from Renewable Resources (TV G)

Partners • California Governor’s Office of Business and

Economic Development, Tyson Eckerle

• California Air Resources Board, Andrew Martinez

• California Energy Commission, Jean Baronas

• South Coast Air Quality Management District, Joseph Impullitti

• Sam Sprik, NREL, PI NREL | 3

Relevance

Hydrogen and fuel cell stakeholders worldwide are using California’s experience as a model case, making success in California paramount to market acceleration and adoption. The technical research capability of the National Renewable Energy Laboratory will be used to assist California in decisions and evaluations, as well as to verify solutions to problems impacting the industry. Because these challenges cannot be addressed by one agency or one laboratory, a hydrogen research consortium has been organized to combine and collaborate. The collaboration aims to:

• Ensure that data are available to evaluate projects and inform decision makers

• Independently verify and validate component solutions

• Provide experimental results for future hydrogen infrastructure

• Increase the availability of technical experts for quick-need issues for California hydrogen infrastructure development, deployment, operation, and technology advances.

NREL | 4

Approach: Cross-cutting R&D objectives with multiple stakeholders

Regular communication and collaboration with research partners enables flexible, real-time identification of needs and project progress addressing hydrogen infrastructure gaps related to portions of the H2@Scale concept.

NREL | 5

Approach: Integrated with H2@Scale Topics

Research Task 3: H2 Contaminant Detector

Research Task 4: Nozzle Freeze-Lock

STORE Improved Bulk Storage Technologies

Research Task 1: Data Collection & Analysis Research Task 5:

CA H2 Integration Research Task 2: Medium/Heavy-Duty Fueling

Research Task 6: Technical Assistance

NREL | 6

Approach: Utilize NREL Core Capabilities

R&D tasks leverage existing capabilities

Low/Med/High Pressure Storage and Compression

HD Fueling National Fuel Cell Technology Evaluation Center (NFCTEC)

Chilling/Dispensing

Lab Research FCEVs

Electrolysis

Veh Tank Simulator

H2@Scale

NREL | 7

Approach: Reporting

Frequent updates/reporting within the consortium and to the public is key to sharing research learnings and leads to new areas of interest.

Reporting includes:

• Monthly research status webinars with consortium • FuelCell Seminar presentations • H2@Scale working group presentations • Final reports.

Results

Monthly updates • Project Status • Q & A • Topics of interest

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Approach: Research Divided into 6 Tasks

Task 1: Station Data Collection & Analysis

12 months, $40k DOE, $40k CA PI – Genevieve Saur

• Analysis and reporting on current hydrogen station data

while setting up data needs for future projects.

Task 2: Medium/Heavy-Duty Fueling

12 months, $150k DOE, $50k CA PI – Mike Peters • Analysis of truck fueling needs and operation

Task 3: H2 Contaminant Detector

24 months, $300k DOE, $100k CA PI – Bill Buttner

• •

•

Down-select and order HCD

Complete verification of HCD operation with pre-mixed

gases

Integrate HCD into NREL’s HITRF for in-situ operation (1

– 12 months)

Task 4: Nozzle Freeze-Lock Evaluation

6 months, $10k DOE, $60k CA, $75k Industry PI – Shaun Onorato

•

•

Review, build, and commission experimental ambient

control test platform

Complete nozzle experiment to benchmark failure

frequency and condition (ambient temperature and

humidity) and publish results

Task 5: CA Hydrogen Integration

12 months, $30k DOE, $20k CA PI – Mariya Koleva

• •

•

Collect CA stakeholder needs

Report on existing hydrogen integration data and

analyses results that address needs

Identify gaps and possible future analyses

Task 6: Technical Assistance

12 months, $10k DOE, $30k CA PI –Sam Sprik

•

•

Check in with project partners for brief projects in need

of national lab technical expertise

Project chosen: Updating HySCapE algorithms

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NREL’s National Fuel Cell Technology Evaluation Center

Approach: NFCTEC Data/Analysis/Results

Handling

CDPs

DDPs

Composite Data Products (CDPs)

• Aggregated data across multiple systems,

sites, and teams

• Publish analysis results without revealing

proprietary data every 6 months2

Detailed Data Products (DDPs)

• Individual data analyses

• Identify individual contribution to CDPs

• Only shared with partner who supplied

data every 6 months1

Results

Internal analysis

completed quarterly

Bundled data (operation and

maintenance/safety)

delivered to NREL quarterly

Confidential Public

1) Data exchange may happen more frequently based on data, analysis, and collaboration

2) Results published via NREL Tech Val website, conferences, and reports

CDPs published with data through 2019Q3 and 2020Q2 NREL | 10https://www.nrel.gov/hydrogen/hydrogen-infrastructure-analysis.html

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H2 Station Data Analysis

Sampling of Results

102 Composite Data Products in 8 topic areas publicly available https://www.nrel.gov/hydrogen/hydrogen infrastructure analysis.html

Fueling Rate Average 0.9 kg/min

Fueling Amount Average 3.01 kg

Fueling Time Average 3.39 min

Compressor Energy Average 1.38 kWh/kg

Total Hydrogen Dispensed (35 Stations)

2,751,081 kg 2,107,471 kg - 19Q3

Maintenance Cost per Station per Quarter Average

$9,955 per station-quarter $8,782 (last 8 quarters)

Maintenance Hours Average 88 hours/Quarter 94 hrs/Qtr (last 8 quarters)

Fueling Final Pressure Average 758 bar

Average Electricity Cost by Delivery Type 2020Q2

$3.05/kg – Compressed $4.02/kg – Liquid

$3.65/kg –Electrolysis

For more hydrogen station analysis see AMR #TA042

NREL | 11

Accomplishments & Progress: M/HD Fueling

This task focused on M/HD hardware

lessons learned and gap analysis using

information gathered from multiple

projects at NREL related to HD.

• Several webinars and a workshop

informed California agencies of the

current status of projects at NREL

including opportunities/challenges

related to medium and heavy-duty

hydrogen

• Graphic created by NREL showing

synergy from development of both

light and heavy-duty hydrogen market

segments leads to improvement in

each value proposition

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Accomplishments & Progress: M/HD Fueling

MD/HD Hydrogen Applications Workshop for California agencies • Educational resource for California State and local government staff.

• ~80 attendees

Topics covered:

• Life Cycle Implications of HD Vehicles Future target of 10kg/min for hydrogen fueling of trucks requires • Medium- and Heavy-Duty Transportation R&D performance and safety to be well understood through R&D • Overview of SERA Model

• Applications SERA for FCEV Adoption

• Market Segmentation

• Hydrogen Financial Analysis Scenario Tool (H2FAST)

• Hydrogen Stations and DC Fast Charging

• Hydrogen Station and Vehicle Field Data

Source: https://www.californiahydrogen.org/wp-content/uploads/2017/10/CHBC-FCET-Fact-Sheet_Final-1.pdf

NREL | 13Model of H2 Tank Fueling

Diesel, Electric and Hydrogen Truck Range Comparison for 10 Minutes of Fueling

Approach: HCD Task Hydrogen Contaminant Detector Integration at Fueling Station: Concept

See Project ID #h2042 “Hydrogen Contaminant Detector” for more details

The in-line Hydrogen Contaminant Detector. The HCD will automatically analyze for hydrogen

fuel quality following every fill using the NREL HCD-I concept

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Accomplishments & Progress: HCD Task Objective: Implement an in-line hydrogen contaminant detector (HCD) within a hydrogen fueling dispenser that can verify in near real-time the concentration of regulated hydrogen impurities as prescribed by SAE J 2719.

Progress: Selected two instruments, verified performance, built working model to interface with station

and sample station gas (HCD-I).

HCD-1 is a commercial FT-IR instrument capable of verifying the concentration of multiple impurities is within the level prescribed by J2719. Laboratory performance evaluations generated calibration curves for carbon monoxide (CO), carbon dioxide (CO2), water (H20) and ammonia (NH3). HCD-2 is a carbon monoxide specific sensor developed by Las Alamos National Laboratory to quantify the level of CO in hydrogen fuel, and its performance was verified by laboratory analysis at NREL.

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Commercial FTIR (multi-gas HCD)

LANL EC Sensor Carbon Monoxide HCD

See Project ID #h2042 “Hydrogen Contaminant Detector” for more details

Accomplishments & Progress: Nozzle Freeze-Lock

Objective: Create an environmentally controlled test setup for identifying conditions leading to nozzle

freeze-lock and for verifying solutions.

Outcome: A new capability was designed and fabricated at NREL’s HITRF facility to test and evaluate hydrogen nozzles under specific temperature and dew point temperature settings. The following NREL

capabilities were leveraged:

1. HITRF Hydrogen Station - Hydrogen generation, compression, storage, chilling, etc.

2. Air Products (APCI) Hydrogen Dispenser - H35 & H70 fueling per SAE J2601

3. Hydrogen Vehicle Tank Simulator (HyVS) – Hydrogen storage tanks to simulate 5 FCEVs

4. Research hydrogen dispenser - Hydrogen recirculation to station

The Project was executed in 3 phases:

I. A baseline analysis was completed using a matrix of temperatures and associated dew points starting with ISO/DIS 17268 protocols.

II. A revised test matrix was derived based on Phase I results and additional temperatures/dew points were evaluated.

III. A revised test matrix was issued beyond ISO/DIS 17268 based on results to evaluate new nozzle designs for manufacturers and station operators.

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Accomplishments & Progress: Nozzle Freeze-Lock

Acronyms: CGT - Combustible Gas Transmitter C1D2 - Class 1 Division 2 Boundary HV - Hand Valve HyVS - Hydrogen vehicle simulator PSH/L – Pressure Switch High/Low RHT - Relative Humidity Transmitter VFD - Variable Frequency Drive SCR – Steam Generator Controls TT - Temperature Transmitter

Test Stand Design and Test Parameters:

• Test stand comprised of an atmosphere generating cart connected to an

atmospheric chamber attached to HyVS (see schematic and figure to right).

• Testing plan derived from ISO/DIS 17268 and SAE J2601 protocols.

• Test set points (temperature & dew point) evaluated over 10 fills unless 2

consecutive freeze events occurred, then test concluded.

• Freeze event was >10 seconds to disengage nozzle.

• Qualitative measure of force to disengage (freeze, difficult, strained, & normal).

Nozzle Freeze-Lock Test Plan Parameters

NREL | 17

Accomplishments & Progress: Nozzle Freeze-Lock

Progress: Testing concluded in winter 2020. A draft report was issued

to partners in 2021 for review and will be released for publication on

the NREL website in 2021.

Results:

• Freeze-lock occurrence appears more likely at ambient

temperatures of 35°C-40°C.

• Freeze-lock occurrence by dew point temperature appears more

likely at 20°C-30°C.

• Freeze-lock appears more likely between fill numbers 3-6 of 10

total fills (per test plan).

Freeze-lock Testing Statistics:

• Number of freeze events: 41 of 157 fills (26%) • Temperature with most frequent freeze events: 35°C (10

events) • Dew point temperature with most frequent freeze events:

30°C (11 events) • Freeze-lock average time: 25.3 secs • Longest observed event: 90 sec at 35°C and 30°C Dew Point

20°C-30°C. NREL | 18

Figure. Nozzle condition comparison for all factors of test temperature, dew point, and fill number. Smaller circle size represents the percentage of

observed event, plotted against number of total observed events (large circle size) of the test set point. Freeze-lock events are shown in red and appear more likely at test temperatures of 35°C-40°C and dew points of

Accomplishments & Progress: Nozzle Freeze-Lock

Results Continued: Nozzle Freeze-Lock Test Matric Phases I & II • As part of phase III of the nozzle freeze-lock evaluation, NREL

should recommend a test sequence for evaluating future nozzle

designs.

• Based on the test results and the original test matrix (shown at

right) a suggested table of tests for nozzle evaluation is shown

(bottom right). The evaluation table shows the recommended

sequence with “Test 1” indicating the first round of set points to test followed by rounds “2” and “3”.

Lessons Learned/Future Work: Recommended Test Conditions and Sequence for Nozzle Evaluation

• Repeated testing and evaluation multiple nozzle manufacturers needed to establish statistical significance and observe trends.

• Incorporate nitrogen purging at nozzle holster in evaluations per industry best practice.

• Freeze-lock cart will be utilized for heavy-duty hydrogen nozzle evaluations in fiscal year 2021/2022.

• Potential to align freeze-lock data with industry data and develop forecasting based on current weather conditions for station operators.

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Accomplishments & Progress: H2 Integration

Objective

To provide data and analysis to inform California decision and

policy makers about the benefits and gaps of integrating

hydrogen into the state's energy management plan.

Topics Analysis

• Overview of electrolyzers and other existing hydrogen

production technologies

• Investigation of the duck curve and H2@Scale for addressing

it

• Affordable pathways for hydrogen integration in centralized

and decentralized markets

Progress

• Final report “California Hydrogen Integration” submitted to

partners for internal use. NREL | 20

Accomplishments : Tech Assistance

The tech assistance task was assigned to investigating updates to

the Hydrogen Station Capacity Evaluation (HySCapE) tool.

• First task was to investigate cryopump flow rates based on

variable density of liquid h2

• Algorithms were developed and implemented in offline

code for future use in models that support

thermodynamics (not viable in current version of

HySCapE).

Process for determining the density of the liquid hydrogen that affects the mass flow rate from cryopump. NREL | 21

Accomplishments : Tech Assistance

2nd task was to be able to handle M/HD demand

profiles and vehicles in HySCapE within the light duty

station model.

• Updates in offline code can now use multiple

demand profiles and different tank sizes onboard

the vehicles but it was not implemented in the

public version to not interrupt the current usage of

HySCapE for light duty. Will come in useful for

future work where we will build the station

capacity tool for heavy-duty.

• Fills >10kg, demand profile different than Chevron

profile.

• Now have an example that uses a flat/constant

demand profile with no variations during the day.

• Doubled the tank size on the vehicles being fueled

to 252 liters (10kg).

• Updated GUI list now includes and loads MDHD

profile.

• Kept flow rate at 1kg/min for now.

Updated offline version of HySCapE for larger vehicle tank sizes and M/HD demand profiles

NREL | 22

Accomplishments and Progress: Response to Previous Year Reviewers’ Comments

• Project was not reviewed last year.

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Collaboration and Coordination

• California Air Resources Board (CARB) • California Energy Commission (CEC) • South Coast Air Quality Management District (SCAQMD) • California Governor’s Office of Business and Economic

Development (GO-Biz) This group of CA agencies identified a need to leverage national laboratory research capabilities to support their hydrogen efforts. The consortium identifies research tasks based on needs and priorities for the California agency partners. Focus is placed on sharing and translating lessons learned to other jurisdictions, which is a priority in this partnership between state and federal agencies and laboratories.

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Remaining Challenges and Barriers

• Hydrogen contaminant detectors are not expected to meet all requirements of SAE J2719

• Review/approval/finalization of reports.

– Publication and presentation of results is an important metric for the research tasks in order to provide data to stakeholders. Although reports are shared within consortium, publication to general public is not guaranteed to be approved by all parties.

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Proposed Future Work

Task Name Potential Topics

HD Reference Station Design

•

•

Develop reference station designs for heavy-duty hydrogen

vehicles

This task will be led by Sandia National Lab

HD Station Test Device Design • Establish design requirements for a heavy-duty hydrogen station

test device to analyze hydrogen fueling performance

H2 Contaminant Detector

•

•

•

Focus on water vapor contaminant sensing at stations in HCD

equipment as more electrolysis stations are expected

Ensure compatibility of HCD pneumatic system with regulated

contaminants

Validating HCD in the field at a CA station

HD Station Capacity Tool • Develop a heavy-duty hydrogen station capacity model with

70MPa fueling

Any proposed future work is subject to change based on funding levels.

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Summary

• This consortium coordinates research efforts that: – supports the DOE’s and CA hydrogen goals and requirements – shares lessons learned with other states to inform implementation efforts outside

of California – supports shifting the hydrogen infrastructure progress from a government push

into a market pull – advances the station technology and operation to meet the next waves of vehicle

demand – leverages existing core capabilities and researchers – shares findings from research tasks with stakeholders

• All but one research tasks from the first phase are complete. One task (HCD) has a 2-year commitment that is going through 7/31/2022.

• Future research tasks are in contracting stage and will focus on HD reference station layout, HD station testing device, HD station capacity tool, and HCD. Labs included in proposed future work include NREL, SNL and ANL.

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Thank You

www.nrel.gov

This work was authored by the National Renewable Energy Laboratory, operated by Alliance for Sustainable Energy, LLC, for the U.S. Department of Energy (DOE) under Contract No. DE-AC36-08GO28308. Funding provided by U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Hydrogen and Fuel Cell Technologies Office. The views expressed in the article do not necessarily represent the views of the DOE or the U.S. Government. The U.S. Government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for U.S. Government purposes.

Technical Backup and Additional Information

Technology Transfer Activities

• None at this time

• Potential: In-line hydrogen contaminant device for integration at hydrogen stations.

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Progress toward DOE Targets or Milestones

• The benefits of this consortium begin with coordinated research efforts that:

– support the DOE’s and CA energy goals and requirements – share lessons learned with other states to inform

implementation efforts outside of California

– support shifting the hydrogen infrastructure progress from a government push into a market pull

– advance the station technology and operation to meet the next waves of vehicle demand

– explore local sourcing for increased renewable hydrogen

NREL | 31