Periodic Reporting for period 1 - RHeaDHy (Refuelling Heavy Duty with very high flow Hydrogen)
Reporting period: 2023-02-01 to 2024-07-31
High-performance hydrogen refuelling stations can contribute to the European Union (EU) transport decarbonisation ambition. The EU-funded RHeaDHy project will develop high-flow components and refuelling line to implement and test new high-flow refuelling protocols that allow refuelling of 100 kg hydrogen trucks at 700 bar within 10 minutes. It will apply a comprehensive approach to guarantee optimal design of the refuelling line and the components from downstream high-pressure refuelling station storage to vehicle storage. RHeaDHy will also perform extensive simulation work to calculate refuelling coefficients specific to vehicle storage and install two high-flow refuelling lines in France and Germany within the first two-and-a-half years.
To reach these ambitious goals, nine partners from three European countries are involved (See the attached Figure). With eight industrial partners and one research organisation, this project is mainly for operational purposes.
The consortium already defined the specification of all the components of the refuelling line and associated simulations were conducted to validate their behaviour during refuelling. Currently, partners are building/assembling the main components of the high flow refuelling line.
The RHeaDHy project is built around five main objectives:
1. Design and assembly of a very high flow hydrogen refuelling line
The consortium achieved significant progress on the goal by first outlining the initial design of the new H2 line and then detailing the specifications for each component in the H2 Refuelling station. Currently, most of the components are being prototyped and/or tested.
2. Develop new components needed for high flow refuelling
The design phase for all essential parts of the high flow refuelling line has been completed. Presently, focus has shifted to supply and manufacturing, which will remain priorities throughout the second phase of the project. Initial testing on the Break-away / Flexible / Nozzle-receptacle components yielded promising outcomes. About the communication technology to be tested during the project, a first benchmark of suppliers was made and selection of the better solution is ongoing.
3. Development and demonstration of a new protocol to refill storage system
An assessment of existing protocols and those currently under discussion in standardization committees has been conducted to create a shortlist for testing within the RHeaDHy project.
4. Fast and efficient refill of storage systems with H2 at low cost
The finalization of the first three objectives is necessary before we can begin addressing this objective. However, in order to keep a good understanding of the prices and not be to fare from the final objectives, the cost study will be started earlier (In 2025) than initially planned (Mid 2026).
5. Standardize and certify components for HRStation to ensure a fast deployment
Consortium members are present and active in all the consortium committees related to the components developed in order to guarantee standard compatibility.
To reach these ambitious goals, nine partners from three European countries are involved (See the attached Figure). With eight industrial partners and one research organisation, this project is mainly for operational purposes.
The consortium already defined the specification of all the components of the refuelling line and associated simulations were conducted to validate their behaviour during refuelling. Currently, partners are building/assembling the main components of the high flow refuelling line.
The RHeaDHy project is built around five main objectives:
1. Design and assembly of a very high flow hydrogen refuelling line
The consortium achieved significant progress on the goal by first outlining the initial design of the new H2 line and then detailing the specifications for each component in the H2 Refuelling station. Currently, most of the components are being prototyped and/or tested.
2. Develop new components needed for high flow refuelling
The design phase for all essential parts of the high flow refuelling line has been completed. Presently, focus has shifted to supply and manufacturing, which will remain priorities throughout the second phase of the project. Initial testing on the Break-away / Flexible / Nozzle-receptacle components yielded promising outcomes. About the communication technology to be tested during the project, a first benchmark of suppliers was made and selection of the better solution is ongoing.
3. Development and demonstration of a new protocol to refill storage system
An assessment of existing protocols and those currently under discussion in standardization committees has been conducted to create a shortlist for testing within the RHeaDHy project.
4. Fast and efficient refill of storage systems with H2 at low cost
The finalization of the first three objectives is necessary before we can begin addressing this objective. However, in order to keep a good understanding of the prices and not be to fare from the final objectives, the cost study will be started earlier (In 2025) than initially planned (Mid 2026).
5. Standardize and certify components for HRStation to ensure a fast deployment
Consortium members are present and active in all the consortium committees related to the components developed in order to guarantee standard compatibility.
After 18 months of effort, RHeaDHy has already accomplished significant achievements. The first action undertaken within this project had been to define all the requirements of the complete hydrogen refuelling station. It had resulted in the definition of all the requirements to design each component.
• Break away, Hose, Nozzle, Receptacle: The first tests conducted on prototype products from external partners Stäubli and Spir Star, showed promising results. They were properly integrated by HRS, with no leaks detected and their functionality has been proven. A second batch of tests is foreseen soon to be able to quantify their pressure drop. HRS is for both valves and the air actuated PCV. The first prototype has been assembled and sent for security testing (e.g. burst testing).
• Truck Storage Test System (TSTS): FAURECIA has frozen the specification of the tanks assembly offering the 100 kg of H2 storage necessary for this project. The tanks production is ongoing.
• Communication interface: A benchmark of suppliers was made in order to identify all the possible communication technology possible. After a detailed comparison with various communication solutions, some viable options were shortlisted: a combination of Bluetooth and Ultra-Wide Band (UWB), bi-directional infrared, and a combination of WiFi and NC. Investifations are ongoing to finalize the selection of the best communication technology.
Part of this project relies on modelling conducted by ENGIE either to support partners in optimizing their components or to integrate the protocols to the truck storage test system.
The consortium is also preparing for the market launch by actively participating in relevant standardization committees and planning close interactions with a selected group of experts unified in an advisory board.
• Break away, Hose, Nozzle, Receptacle: The first tests conducted on prototype products from external partners Stäubli and Spir Star, showed promising results. They were properly integrated by HRS, with no leaks detected and their functionality has been proven. A second batch of tests is foreseen soon to be able to quantify their pressure drop. HRS is for both valves and the air actuated PCV. The first prototype has been assembled and sent for security testing (e.g. burst testing).
• Truck Storage Test System (TSTS): FAURECIA has frozen the specification of the tanks assembly offering the 100 kg of H2 storage necessary for this project. The tanks production is ongoing.
• Communication interface: A benchmark of suppliers was made in order to identify all the possible communication technology possible. After a detailed comparison with various communication solutions, some viable options were shortlisted: a combination of Bluetooth and Ultra-Wide Band (UWB), bi-directional infrared, and a combination of WiFi and NC. Investifations are ongoing to finalize the selection of the best communication technology.
Part of this project relies on modelling conducted by ENGIE either to support partners in optimizing their components or to integrate the protocols to the truck storage test system.
The consortium is also preparing for the market launch by actively participating in relevant standardization committees and planning close interactions with a selected group of experts unified in an advisory board.
The RHeaDHy project is structured around two main outcomes: the full development of Hydrogen Refuelling Station components up to the commercialization stage, and the complete integration of the specific chain for Heavy Duty Vehicles Hydrogen Refuelling Stations, including new standardized refuelling protocols. Currently, the components have been designed and are set to be manufactured during the project's second phase. Therefore, the outcomes have not yet been fully realized. This is not only beneficial for their existing customers but also opens up opportunities to access new markets.