Session 1.4: Automotive Design Aspects and … · Session 1.2: Introductory Lectures K. Hall Session 1.4: Automotive Design Aspects and Requirements Requirements and Design Aspects

Session 1.2: IntroductoryLectures

K. Hall

Session 1.4: Automotive Design Aspects and Requirements

Requirements and Design Aspects for Automotive Liquid Hydrogen StorageM. Stoecklin

25th – 29th September 2006Ingolstadt

Session 1.4 Automotive Design Aspects and Requirements Michael Stoecklin 2

CV – Michael Stoecklin

Address:BMW GroupResearch and Technology80788 München

Following my studies for mechanical engineering, I entered BMW Group in 1997. After 3 years as project engineer passive safety in the series development, I joined the hydrogen research and technology department in 2001, developing car safety concepts. From end of 2003 until early 2006 I worked in Tokyo/ Japan as technology scout hydrogen. Since my return I am responsible again for hydrogen safety and are the BMW project leader of HySafe, a European network of excellence.

1.4 Automotive Design Aspects and Requirements


Internal Combustion Engine and Liquid Hydrogen,the BMW Approach, Michael Stoecklin (BMW)Abstract:

BMW Group has been continuously working on hydrogen vehicles and their infrastructure for over 25 years. Having demonstrated the technical feasibility with a small fleet during the BMW CleanEnergy world tour in 2001, the development of the 6th generation, which will be launched in the near future, was shifted from the research into the series development departments.All BMW hydrogen vehicles have been powered by a bifuel internal combustion engine being able to use either gasoline or hydrogen, which is stored in its liquid form at -253°C offering the highest energy density.BMW is also working on fuel cells but as an auxiliary power unit (APU) e.g. to run the air-condition system during standstill of the engine.The presentation will give detailed background information and explain BMW’s hydrogen strategy.

1.4 Automotive Design Aspects and Requirements


Requirements and Design Aspects for Automotive Liquid Hydrogen Storage

M. Stoecklin

Table of Content

Hydrogen Vehicles at BMWAutomotive Energy Storage SystemLiquid HydrogenPowertrainInfrastructure


Potential of Hydrogen ICEBMW Record Drive, September 2004

Length: 5,60 mWidth: 2,00 mWeight: 1560 kgcx: 0,21Engine: V12, 6 litre

monovalent H2

Power: > 200KW

AccelerationAcceleration: 0: 0--100km/h in 6 s100km/h in 6 s

VmaxVmax = 302,4 km/h= 302,4 km/h


Hydrogen Research VehiclesFive Gerneration from 1979 - 2002


Commitment CleanEnergyCleanEnergy WorldTour 2001 + 2002

DubaiDubai BrusselsBrussels MilanMilan

TokyoTokyo Los AngelesLos Angeles BerlinBerlin

SacramentoSacramento LondonLondon JohannesburgJohannesburg


Series Development of 6th GenerationBi Fuel Concept for First Market Introduction

Internal Combustion

Engine

Liquid HydrogenTank

GasolineTank


The Optimal Automotive Fuel SystemRequirements

High energy density for broad driving rangeFreedom of shaping for packageLow weightMinimal energy loss during standstill of carHighly dynamic for changing energy demandEasy and quick refuelingFunctional and passive safetyDurabilityLow cost…

Infrastructure available


StorHy Targets 2010Requirements for LH2 / ICE-System

989899%Purity

5.5kg H2/minDelivery Rate

35101.5barMinimium Pressure

-30 / +85-20 / +85-40 / +85°COperatingTemperature

2.06.01.54.5

1.54.51.23.6

2.06.01.54.5

kWh/kgwt%kWh/lkgH2/100l

Storage SystemGravimetric Density

Volumetric Density

DOE2010

DOE2005

StorHy


Alternative FuelsEnergy Equivalent Gasoline / Hydrogen

Any shape

15 kg 165 kg < 40 kg170 kg 126 kg

3xCFRP-Tank(Quantum Typ IV)

2xCFRP-Tank(Lincoln)

Gasoline43 MJ/kg

Gaseous Hydrogen120 MJ/kg

Liquid Hydrogen120 MJ/kg

CGH2350 bar

CGH2700 bar

LH2-253 °C, 3-5bar35 l

430 l 256 l 160 l

27 kg 10 kg 10 kg

=^700km range„5l-car“ =^

Steel(H2R)

CFRP(StorHy)


H2-Storage in the VehicleVolumetric energy density of LH2 and GH2

Volumetric Energy Density[kWh/l]Volumetric Energy Density[kWh/l]

2,52,5

WorkingPointWorkingPoint2,02,0

1,51,5

1,01,0

0,50,5

0010001000100100

Pressure [bar]Pressure [bar]10105511

Liquid Hydrogen(Equilibrium)

Liquid Hydrogen(Equilibrium)

GaseousHydrogen (280K)

GaseousHydrogen (280K)Critical

PointCriticalPoint


Mobile Hydrogen StorageDOE Targets

0 5 1010

20

30

40

50

60

70

80

4 bar

1 bar

1000bar

700 bar

350 bar

2015

2005

2010

DOE LH2 (today) LH2 (future) CGH2 (today) CGH2 (future) Chem.Hyd. (today) MH (today) MH (future) Physics CGH2 Physics LH2

volu

met

ric s

tora

ge d

ensi

ty [k

g / m

3 ]

gravimetric storage density [mass%]

Gasoline(7 series):8 kWh/kg

(-> 24mass% H2)9 kWh/L (270kg/m³)


Hydrogen Storage in the VehicleLiquid Hydrogen

Level Probe

Outer Vessel

Inner Vessel

Coupling

Filling Line

System Box

cooling waterheat exchanger

Suspension

Heater


Hydrogen StorageState of the art / Future Tank System

Future System• Stainless steel• Cylindrical vessels• Plant specific design

• Lightweight materials• Free form geometry• Automotive design • Reduced heat entry

Challenges::• Vacuum stability• Material properties• Thermal shock• RecyclingState of the Art


StorHy: EU Funded Project at BMWH2 Storage for automotive applications

Highpressurebei 700 bar

Cryogenicbei -253 °C

Solid storage

Duration: 4,5 YearsBudget: ~ 20 Mio. €


Automotive Hydrogen CouplingJoint Development with GM

„Development of a standardised LH2-filling system for autocars.“


Hydrogen Combustion EngineClean and Powerful

Ø Power density

Ø Power characteristic

Ø Efficiency

Ø Reliability

Ø Cost

Ø Well Known


Hydrogen Combustion EngineResearch Activities

High-pressure direct injection(~ 200 bar)

Cryogenic mixture formation(~ –200°C)


Fuel CellsAuxiliary Power Unit

Air-conditioning during stand-still

Immediate heating/warm-up

Communication

Lights

….

“Unlimited” supply of electricity independentof engine operation

Potential:Replacement of alternator and lead acid battery


Hydrogen Fuelled VehiclesChallenges to be Resolved


Munich Airport Hydrogen ProjectFirst Public Hydrogen Filling Station


CleanEnergy Partnership BerlinIntroduction of H2 as Fuel for Road Transport

Testing and Demonstration of:

Production, transport and distribution of H2

Storage and refuelling of H2

Operation and maintenance of H2-Vehicles (FC+ICE)

ΛΗ2

ΧΓΗ2


BMW Hydrogen CarsSummary

Internal Combustion Engine

Proven technology at moderate costs

Still high potential for improvements

Liquid Hydrogen Tank

Highest energy density

Further potential for weight reduction

Small Fuel Cell

Supplement for electric board net

Session 1.2: IntroductoryLectures

K. Hall

Session 1.4: Automotive Design Aspects and Requirements

Requirements and Design Aspects for Automotive Liquid Hydrogen StorageM. Stoecklin

25th – 29th September 2006Ingolstadt

Documents

Session 1.4: Automotive Design Aspects and … · Session 1.2: Introductory Lectures K. Hall Session 1.4: Automotive Design Aspects and Requirements Requirements and Design Aspects