f-cell 2011f-cell 2011, 27.09.2011, bmw group, tobias brunner. seite 2 bmw hydrogen. 30 years of...

F-CELL 2011BMW EFFICIENTDYNAMICS HYDROGEN – PROSPECTS AND CHALLENGES.

Tobias Brunner, 27.09.2011

BMW EfficientDynamicsLess emissions. More driving pleasure.

f-cell 2011, 27.09.2011, BMW Group, Tobias Brunner. Seite 2

BMW HYDROGEN.30 YEARS OF HYDROGEN R&D AND REAL WORLD EXPERIENCE.

1979 2006

PEMFC (APU)

LH2-Refueling

First LH2-ICE Vehicle

LH2 Refueling Station

LH2 Powered ICE

Hydrogen Storage

CleanEnergy World Tour H2R Hydrogen 76 Generations

First LH2-Test Bench

Advancements in Cryogenic and Direct injection


BMW HYDROGEN.6 GENERATIONS OF HYDROGEN VEHICLES:FROM DEVELOPMENT TO FLEET USE.

19792006


BMW HYDROGEN.NUMEROUS LAND-SPEED RECORDS WITH THE H2R RACE CAR SINCE 2004.

The six-liter 12 cylinder hydrogen combustion engine, based on the gasoline power unit featuredin the BMW 760i, developed an output of more than 210 kW or 285 bhp. This accelerated theBMW prototype to 100 km/h in approximately 6 seconds and gave it a top speed of 302,4 km/h (185,52 mph).

The H2R prototype established the following records :

Time in sec - Speed in km/h- Flying-start kilometer : 11,993 - 300,190- Flying-start mile: 19,912 - 290,962- Standing-start 1/8 mile: 9,921 - 72,997- Standing-start ¼ mile: 14,933 - 96,994- Standing-start ½ kilometer: 17,269 - 104,233 - Standing-start mile: 36,725 - 157,757- Standing-start 10 miles: 221,052 - 262,094 - Standing-start kilometer : 26,557 - 135,557- Standing-start 10 kilometers: 146,406 – 245,892


BMW HYDROGEN.FIRST HYDROGEN VEHICLE WORLD TOURS IN 2001 AND 2002.

•


BMW HYDROGEN.HYDROGEN 7: FIRST SMALL SERIES HYDROGEN VEHICLE IN CUSTOMER HANDS.


BMW HYDROGEN.CLEAN ENERGY CAMPAIGN TO MAXIMIZE AWARENESS FOR HYDROGEN VEHICLE TECHNOLOGY.


BMW HYDROGEN 7.STORYLINE.

The BMW Hydrogen 7 is the world’s first premium sedan with a bifueled combustion engine.

The Hydrogen 7 has run through the same product development process as other serial vehicles of the BMW Group.

The Hydrogen 7 is the first premium H2 vehicle to be handed over to users.


BMW HYDROGEN 7.BIFUEL INTERNAL COMBUSTION ENGINE PREMIUM SEDAN WITH A MAXIMUM SPEED OF 230 KM/H IN GAZOLINE AND HYDROGEN MODE.

Maximum speed vmax

Acceleration from 0-100 km/h

Range

LH2

Petrol

230 km/h (cut off)

9.5 sec

> 200 km> 500 km


BMW HYDROGEN 7.CONVERTED THE 7 SERIES TO A BIFUEL CAR.

Vehicle

CFK strengthening in side frame

Hydrogen gas warning system

LH2-fuel tank system

LH2-coupling system

Control System

Boil-off-ManagementSystem

LH2-Storage System

New components

Adapted components

H2-Powertrain

Bifueled internalcombustion engine

Adapted ignition system

Digital Motor Electronics (DME)

H2 mixture generation system


BMW HYDROGEN 7.FEATURING A SERIES CONVERTED V12 ENGINE WITH 260 HP AT 5100 RPM.

6.0 litres

191 kW (260 bhp) at 5100 rpm

390 Nm at 4300 rpm

External fuel-mixture generation

Direct injection

Bifueled 12-cylinder engine (LH2 / petrol)

Capacity

Maximum output

Maximum torque

H2:

Petrol:


BMW HYDROGEN 7.FEATURING A FIRST LIQUID HYDROGEN STORAGE WITH A CAPACITY OF 7.8 KG.

Cryogenic (LH2) at approx. - 250 °C

Double-walled

Vacuum super-insulation with Aluminium reflective foil multi-layer insulation

~ 8 kg extractable H2

< 8 minutes

17 h

9 d

Type:

Shape:

Insulation:

Fuel tank capacity:

Refuelling time:

Start Boil-off*:

Autonomy time*:

*Basis: half-full Tank


BMW HYDROGEN 7.FEATURING A NEW LH2 REFUELING NOZZLE AND BOIL-OFF MANAGEMENT SYSTEM.

Refueling System:

ConsortiumBMW AG, GM, Honda:

Development of a new

nozzle/receptacle

for a LH2 refueling system.

Boil-Off Management System:

development of a new

catalytic boil-off gas

converter system.


BMW EFFICIENTDYNAMICS STRATEGY.4 STEPS TOWARDS EMISSION-FREE MOBILITY.

BMW EfficientDynamicsLess emissions. More Driving Pleasure.

Optimizing:

• Efficiency• Aerodynamics• Lightweight• Energy Management• Road Resistance

ActiveHybrid

ActiveHybrid X6 and Active Hybrid7

BMW i

Battery Electric and Plug-In Hybrid

Hydrogen

Long Range Zero Emission Hydrogen Vehicle


MOTIVATION FOR HYDROGEN.CO2 REDUCTION TARGETS REQUIRE ZERO EMISSION VEHICLE PORTFOLIOS.

Quelle: EU Hydrogen FCV Coalition.


MOTIVATION FOR HYDROGEN.ZEV STORAGE SYSTEM ENERGY DENSITY FAVORS HYDROGEN …

Sys

tem

en

erg

y d

en

sity

[k

Wh/

kg],

[kW

h/L

]

0

2

1

7

Hydrogen Li-Ion Battery

CcH2350 bar

CGH2700 bar

CGH2350 bar

Gasoline

6.9kWh/L

1.2kWh/L

8.9kWh/kg9

2.0kWh/kg

0.8kWh/L

1.6kWh/kg

0.6kWh/L

2.0kWh/kg

0.25kWh/L

0

0.15kWh/kg

cryogenic ambient

5xsmaller

13x lighter

Potential ZEV Storage Systems(Comparison does not include different drive train efficiencies)


MOTIVATION FOR HYDROGEN.ZEV FUEL DISPENSING / REFUELING TIME FAVORS HYDROGEN …

0

50

100

150

200

250

300

Gasoline Hydrogen Electricity50KW2 kg/min50 L/min

2000 km/day

240.000 km/day

80.000

km/day

Ra

ng

e o

f o

ne

dis

pe

nse

r [1

03

km /

day]

Potential ZEV Fuels


MOTIVATION FOR HYDROGEN.H2 REFUELING COST PROJECTED TO BECOME COMPETITIVEIN THE LONG TERM….

0

5

10

15

Delivered at Pump w/o taxes and excisesHydrogen CostEUR/kg

2050204520402035203020252020

4.44.44.5

2015

4.75.05.5

6.6

9.9

2010

16.6

Production

Distribution

Retail

Small retail stations operating

at low utilization

1 kg H2 for ~ 100-120 km

long term ~ 3.5 - 4.5 €-ct /km (w/o tax)(4L/100km Diesel today: 6 €-ct/km incl. tax)

Source: EU Hydrogen FCV Coalition.


MOTIVATION FOR HYDROGEN.... BUT WIDE-SPREAD HYDROGEN INFRASTRUCTURE IS STILL YEARS AHEAD.

Germany

• H2 Mobility: Infrastructure Roll-out towards 2015 under investigation.

• Funding for 20 H2 stations announced by industry partners Daimler & Linde.

Japan

• National hydrogen infrastructure roll-out plan:100 Filling Station towards 2015 around 4 megacity regions.

California / CARB states

• CARB/CEC funds initial Infrastructure build-uptowards 2014-2017.

• Regulation to enforce infrastructure roll-out in line with vehicle deployment under investigation (CFO)


MOTIVATION FOR HYDROGEN.… BUT PEM FUEL CELL TECHNOLOGY IS STILL TOO COSTLY.

38,565

9,516

6,296

14,274

2010

81,362

20502020

22,228

2015

3,212

4,3067,475

2,970

18,892

3,194

-77%

-42%

-60%

FC stack lifetime [„000 km] 115 180 247 290

Platinum use [g/kW] 0.93 0.44 0.24 0.11

Key drivers for cost reduction

▪ Innovations in design (e.g.,

reducing complexity).

▪ Different use of materials (e.g., reduced platinum use).

▪ Innovations in production

technology.

▪ Economies of scale.

Source: EU Hydrogen FCV Coalition.

Structure

MEA

(excl. catalyst,

incl. GDLs)

Periphery

Catalyst

(incl. platinum)


BMW ELECTRIC VEHICLE ROLL-OUT.PLUG-IN (HYBRID) ELECTRIC VEHICLES ARE CLOSE TO COMMERCIALIZATION.

MINI E

BMW Concept ActiveE

Fun

ctio

nalit

y &

Mar

keta

bilit

y

2009

BMW i3

2011 2013

BMW i3 Concept 2011

BMW i8

BMW i8 Concept 2011


BMW HYDROGEN TECHNOLOGY.ADVANCEMENT OF CORE HYDROGEN VEHICLE COMPONENTS.

Advanced key components Next vehicle & infrastructureHydrogen 7 small series

LH2 Storage

Capacity

Safety

Boil-off loss

Pressure supply

Complexity

Infrastructure

Technology Leap Storage & Drive train

Long-range ZEV Mobility:

Zero Emission.

Focus on vehicles with high

energy demand.

Range > 500 km (6-8 kg H2)

Fast refueling (< 4 min / 7 kg)

Optimized safety oriented vehicle package & component integration

Loss-free operation for all

relevant use cases

Compatibility to competitive

infrastructure standards

IC Engine (PFI)

Power density

Dynamics

Durability & cost

Efficiency

H2 Drive train

H2-Storage

Electrification

H2ICE H2HEV EREV FCHV FC-EREV

AdvancementKey Components

CGH2LH2CcH2


BMW HYDROGEN TECHNOLOGY.HYDROGEN INTERNAL COMBUSTION ENGINE TECHNOLOGY STATUS: DOUBLE POWER DENSITY COMPARED TO HYDROGEN 7 ICE ON TEST BENCH.


BMW HYDROGEN TECHNOLOGY.STATUS OF SMALL FUEL CELL TECHNOLOGY (5 KW): EFFICIENCY, DYNAMICS, DURABILITY AND FREEZE START VALIDATED.

UTC5KW

PEMFC


BMW HYDROGEN TECHNOLOGY.STORAGE TECHNOLOGIES: ONLY PHYSICAL STORAGE SYSTEMS VALIDATED FOR USE IN PASSENGER VEHICLE.

Physical Storage Solid storage

Single or multi-

pressure vessel

700 (350) bar

Liquid Adsorption

„activated

carbon“

Hydrides

„MOFs“„chemical“

„Zeolith“„organic“

„metallic“

Compressed

CGH2* LH2

*

Source: BMW

Super-insulated

low-pressure Cryotank

Research level!Demonstration level

Small Series level,

Mainstream

Source: Quantum

CcH2*

Source: BMW

Cryo-compressed

Super-insulatedcryogenic pressure

vessel 350 bar

Prototype level

„organic“

*) CGH2 := Compressed Gaseous Hydrogen (700bar) CcH2 := Cryo-compressed Hydrogen (10bar - 350bar) LH2 := Liquid/Liquefied Hydrogen (1 bar_a - ca. 10 bar_a)


BMW CRYO-COMPRESSED HYDROGEN STORAGE PROTOYPE 2011.

CRYO-COMPRESSED HYDROGEN STORAGE.

Modular Super-insulated Pressure Vessel (Type 3) to Store Cryogenic Gas

Max. usable capacity

CcH2: 7.8 kg (260 kWh)CGH2: 2.5 kg (83 kWh)

Operating pressure

350 bar

Vent pressure ≥ 350 bar

Refueling pressure

CcH2: 300 barCGH2: 320 bar

Refueling time< 5 min for 7.8kg (equivalent to J2601)

System volume ~ 235 L

System weight (incl. H2)

~ 140 kg

H2-Loss (Leakage| max. loss rate | infr. driver)

<< 3 g/day | 3 – 7 g/h (CcH2) |no significant losses

+ Active tank pressure control

+ Load carrying vehicle body integration

+ Engine/fuel cell waste heat recovery

Vacuumenclosure

Aux. systems(control valve, regulator, sensors)

MLI insulation(in vacuum space) Refueling line

Shut-off valve

Intank heatexchanger

Suspension

Coolant heatexchanger

Pressure Vessel (Type 3)

Secondary vacuum module(shut-off / saftey valves)


CRYO-COMPRESSED HYDROGEN STORAGE.SIGNIFICANT MAXIMUM CAPACITY ADVANTAGE OVER COMPRESSEDGASEOUS STORAGE AT 700 BAR.

7.8 kg* CcH2

140 kg system**

*) maximum usable H2-mass with 10 bar power train supply pressure. **) based on prototype 2011, including BOT & BOP

Cryo-compressed Hydrogen - CcH2

Com

pre

ssed

Gas

eous

Hyd

roge

n -

CG

H2

2200 mm

346

mmdesign space

> 80% higher max. usable storage

capacity in given design space.

4.3 kg* CGH2

90 kg system


CRYO-COMPRESSED HYDROGEN STORAGE.SAFETY ASPECTS: DOUBLE LAYER PROTECTIVE DESIGN, REDUNDANT SAFETYDEVICES AND LOW EXPANSION ENERGY EXHIBIT A HIGH SAFETY LEVEL.

Vacuum enclosure & safety release control Low adiabatic expansion energy

Vacuum enclosure design lowers risk of pressure vessel damage (mechanical and chemical intrusion,

bonfire damage and aging) and enables leak monitoring.

Redundant safety devices for controlled hydrogen release in case of damage or vacuum failure.

Cryogenic hydrogen contains a low adiabatic expansion energy and thus, can mitigate implications of a

sudden pressure vessel failure, in particular during refueling.

Ad

iab

atic

exp

ansi

on

en

erg

y [k

Wh

/kg

]

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

CcH2

Full CcH2 storage

after cold refueling

6-15 times

lower expansion

energy

Ambient CGH2

storage after refuelingVacuum Enclosure

Redundant Safety Devices

COPV in vacuum environment


CRYO-COMPRESSED REFUELING.REFUELING VIA HIGHLY EFFICIENT LH2 HIGH PRESSURE PUMP: DURABILITY VALIDATION RUNNING SINCE 04/2010.

BMW Linde CcH2 pump prototype

80 g/L at 300 bar

100 kg H2/h (status)

< 1% LHVcompression energy

In Operation since04/2010

H2 delivered (07/2011): ~ 30 000 kg (> 6000 refuelings withsubscale and full size tank systems)


CRYO-COMPRESSED REFUELING.CRYO-COMPRESSED REFUELING UP TO 30 MPA, > 120 KG/H WITH NO NEED FOR COMMUNICATION BETWEEN STATION AND VEHICLE.

Hydraulics

30MPa

Cryo-pump

Quick , direct, non-com refueling to be demonstrated by the end of 2011.

Direct single-flow refueling to

300 bar via cryo-pump

100 -120 kg/h continuous fill rate

( 3 - 3.5 minutes for 6 kg)

No need for communication

between vehicle and dispenser

“… the future for sure is!”

“History can be exciting…”


BMW EfficientDynamicsLess emissions. More driving pleasure.

f-cell 2011f-cell 2011, 27.09.2011, bmw group, tobias brunner. seite 2 bmw hydrogen. 30 years of...

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