UNIVERSITY OF SALERNODepartment of Mechanical Engineering

UNIVERSITY RESEARCH OPPORTUNITIES: ELEMENTS OF HYDRAIL DESIGN

Angelo Esposito, Cesare Pianese, Marco Sorrentinopianese@unisa.it

Fourth International Hydrail Conference

June 9, 2008, Valencia Spain

Agendag

• Energy scenario (Motivations)– Future trends and role of Hydrogen– Well to wheel analysis– Well to wheel analysis

• Hydrogen and Fuel Cells technologies (Solutions)H2 d ti t t t– H2 production, transport, storage

– FC technologies (PEM, SO, PA) for train applications

• Future (R&D)• Future (R&D)– Research needs– Short and medium term visionShort and medium term vision

174

Energy Scenariogy

dia

Security of

Sour

ce: W

ikip

edSecurity ofsupply

S

A il biliPollution

Availability

100Crude oil prices

AffordabilityGlobal

warming Jan 2008

40

60

80

100

$/b

bl

1947 1957 1967 1977 1987 1997 20070

20

40

year

$

175

Future Energy Trendsgy• World energy demand by

Fuel Type eaFuel Type.• Business as usual will lead

to an increase of fossil MB

tu

w.e

ia.d

oe.g

ov/ie

fuels (about 55%) by 2030.

M

Sour

ce:

ww

w

100World Primary Energy Diversification• Oil companies envisage a

di ifi ti

60

80

100m

arke

t COAL NATURAL GAS2005

Com

pany

om

diversification process towards gaseous fuels.

• Methane is the medium

20

40

60

% o

f tot

al m

WOODOIL

SOLAR/H2

ted

from

GH

K C

ww

w.g

hkco

.coMethane is the medium

term solution. • Hydrogen will complete the

t iti f CO f

1850 1900 1950 2000 2050 2100 21500

20

year

NUCLEAR Adaptransition for a CO2 - free

society.176

Hydrogen: advantagesy g g• Energy carrier.gy• Possibility to use any primary source, conventional or

renewable.• Alternative to fossil fuels increasing renewable energy

sources.R d i d d il• Reducing dependency on oil.

• Energy conversion technologies (i e FC) have high• Energy conversion technologies (i.e. FC) have highenergy conversion efficiencies.

• Reduction of GHG without harmful emissions.Reduction of GHG without harmful emissions.• Direct combustion of Hydrogen in thermal engines does

not produce CO, CO2, PM.p 2

177

Well to Wheel AnalysisyThe hydrogen pathway: sources, production and use

SOURCE PROCESS CARRIER USE

WTT TTW

ENTI

ON

AL SOURCE PROCESS CARRIER USE

Mobile

CO

NVE

AutomobileBus

Train

exac

o

BLE

TrainShipPlane

from

Che

vron

Te

REN

EWA Stationary

Pow. Gen.APU

Adap

ted

fAPUCogen.

178

Agendag

• Energy scenario (Motivations)– Future trends and role of Hydrogen– Well to wheel analysis– Well to wheel analysis

• Hydrogen and Fuel Cells technologies (Solutions)H2 d ti t t t– H2 production, transport, storage

– FC technologies (PEM, SO, PA) for train applications

• Future (R&D)• Future (R&D)– Research needs– Short and medium term visionShort and medium term vision

179

H2 production and delivery2 p yShort Term Option Long Term Option

M.O

gden

Afte

r J.

M

180

Onboard Hydrogen Storagey g gHydrogen can be stored in four different ways:

I d f i hi h t k yneT

ek

• In compressed form: in high-pressure tanks or gas cylinders made of ultra-light composite materials; they are used in prototype fuel cell automobiles

Sour

ce: D

y

and buses.• In liquid form: in super isolated tanks as cryogenic

liquid (at -253°C) teyrliquid (at -253 C).

• In a bonded form in a solid compound by:– adsorbing (carbon structures…); ur

ce: M

agna

St

– absorbing (simple crystalline hydrides);– chemically reacting (complex and chemical hydrides).

I fl id d f b h i ll ti

So

r• In a fluid compound form by chemically reacting(e.g. methanol, ammonia, etc).

• Solutions may be chosen according to application

Day

mle

r Chr

ysle

y g ppsecurity issues.

Sour

ce: D

181

Fuel Cells• Fuel Cells are energy conversion systems, which

directly combine H2 and O2 to generate electricity. FCs generate also water and heat O

EFCs generate also water and heat.• FCs have high efficiency (TTW), no moving parts,

simple design, silent operation.

Sour

ce: D

O

p g , p• Auxiliaries are required (BOP) for proper FC stack

working.

nie

& D

icks

ted

from

Lar

min

PEMFC=polymer electrolyte membrane; DMFC=direct methanol; AFC=alkaline; PAFC=phosphoric acid; MCFC=molten carbonate; SOFC=solid oxide.

Adap

t

182

FC Auxiliaries• Appropriate components selection and sizing to meet

application requirements.

H

application requirements.• Optimized working operation to reduce parasitic losses.

humidificationh b

C

H2

H2 tankMFC FC Stack

chamber

heat humidification

fuelcell

stackair

EM

EM

BPV

2

for P

E

exchanger chamberstackC

Tcoolingwaterifi

cati

ater FC: B

OP

f

heatexchanger

P

P

P

hum

idon

w outletwater

watertankam

ple:

P

N2 and O2

tank

Ex

183

Fuel Cell for Rail UseFuel cell technologies• PEMFCs are suitable for both traction and power generation (APU)• PEMFCs are suitable for both traction and power generation (APU).• SOFCs are suitable for APU to generate electric power and heat;

traction can be a long term option.

Advantages• Efficiency (fuel economy and GHG see WTW)Efficiency (fuel economy and GHG, see WTW).• No emissions (toxic and acoustic).• Low infrastructure cost (catenary 2.5 M€/km) and limited

i t l i tenvironmental impact.• Potentially low maintenance costs compared to Diesel.• Few refuelling stations with respect to automobiles. g p• Diesel costs are growing due to the implementation of complex

technologies to control emissions (PM, NOx).

184

FC Hybrid Propulsiony pBenefits

Recovering braking energy for electric• Recovering braking energy for electricpropulsion.

• Batteries allow downsizing the primary energy conversion system.

• Powertrain hybridization could act as a bridge to fuel cell train introduction.a bridge to fuel cell train introduction.

ChallengesDriverDriver

Powercontrolg

• Optimal system integration.• Optimal energy management to

ensure:

DL VMU

Intermediate LevelFC-S-CC-C

High LevelDL VMU

Intermediate LevelFC-S-CC-C

High Level

ensure:– Safe stack operation (avoiding highly

fluctuating load).Ch t i i (t t d b tt

EM

Comp. Humid. …

Intermediate Level

FCS

Low LevelEM

Comp. Humid. …

Intermediate Level

FCS

Low Level

– Charge sustaining (to extend batterylifetime and efficiency). B

Energy Flow DH>0 Energy Flow DH=0

Control Actions Driver Interactions

B

Energy Flow DH>0 Energy Flow DH=0

Control Actions Driver Interactions

PEM Hybrid powertain controlUNISA Multi-level control architecture

High LevelHigh LevelTMUTMU

Intermediate LevelIntermediate Level

FCS

Low Level

FCS

Low Level

FCSFCS

186

Energy Flow DH>0 Energy Flow DH=0

Control Actions Driver InteractionsEnergy Flow DH>0 Energy Flow DH=0

Control Actions Driver Interactions

Agendag

• Energy scenario (Motivations)– Future trends and role of Hydrogen– Well to wheel analysis– Well to wheel analysis

• Hydrogen and Fuel Cells technologies (Solutions)H2 d ti t t t– H2 production, transport, storage

– FC technologies (PEM, SO, PA) for train applications

• Future (R&D)• Future (R&D)– Research needs– Short and medium term visionShort and medium term vision

187

Fuel Cells Research NeedsFuel Cell Stack

Red ce stack costs• Reduce stack costs.• Increase durability.• Increase power density (higher current densities and lower

Trade-off

p y ( gresistance).

F l C ll S t (St k & BOP)Fuel Cell System (Stack & BOP)• Thermal, Air and Water Management• R&D in auxiliary devices: compressor/expanders reformersR&D in auxiliary devices: compressor/expanders, reformers.• Fuel cell system configuration and efficiency.• Start-up time and cold start.• Control and diagnostics; sensors and actuators.• Packaging in vehicle applications.

188

Research TargetsgRoad propulsion• 10 50 times cost reduction:

Stationary5 10 times cost reduction: en

tatio

n Pl

an

• 10-50 times cost reduction:100€/kW (PEM FCS);

• 10 khr durability (Buses).

• 5-10 times cost reduction:1000€/kW;

• 50 khr durability.RAIL

e: H

FP I

mpl

eme

Sou

rce

• Technological/Economical barriers:– Improve electrochemistry (membranes, electrodes, catalysts).– New materials and concept.New materials and concept.– Fluid mechanics (heat and mass transfer).– Economy of scale and technology learning.

• Optimal design/configuration:– Balance of plant.– Hybridization: Mild (APU); Full (Fuel cell + batteries/supercap).

189

Conclusions 1/2• The application of PEM Fuel Cell Systems requires

improvements to reduce costs and improve durabilityimprovements to reduce costs and improve durability.• Transfer of fuel cell technology from automotive to other

markets can contribute to stack cost reduction.markets can contribute to stack cost reduction.• A hydrogen train will only have a 15% extra cost with

respect to ordinary Diesel unit (source: British RSSB)• In the short term PEM is a viable solution for APU.• Hybrid powertrains can be developed in the medium term.

Basic research will focus f fon core technologies to improve materials for performance

enhancement (power density, durability), costs, manufacturing vibration crashworthinessmanufacturing, vibration, crashworthiness.

190

Conclusions 2/2Applied research is needed• to define the role of fuel cell system (traction, APU) and y ( )

proper powertrain solution (e.g. full hybrid, range extender);• to develop and implement ad hoc auxiliary system (BOP);• to customize the plant to meet user requirements (vehicle

layout and configuration);t i hi l i t ti b d h d t• to improve vehicle integration, on-board hydrogen storageand refueling;

• to implement proper control strategies able to maximize FC• to implement proper control strategies able to maximize FCbenefits for energy and emission optimization;

• to develop diagnostics system to guarantee lifelong andto develop diagnostics system to guarantee lifelong andsafe operation;

• to develop FCS computational tools to support both design and engineering phases.

191