Periodic Reporting for period 1 - DelHyVEHR (Delivery of liquid Hydrogen for Various Environment at High Rate)
Période du rapport: 2024-01-01 au 2025-06-30
Renewable hydrogen, particularly in the form of Liquid Hydrogen (LH2), is poised to significantly cut carbon emissions in various industries. LH2 use has grown from space exploration and semiconductors to potentially fueling heavy-duty vehicles (HDVs) like planes, ships, and trains, aiding the EU's net-zero goals. Production of LH2 has surged, doubling in last five years. The DelHyVEHR project aims to design, build and demonstrate a high-capacity LH2 refuelling station, targeting a 5-Tons-Per-Hour flowrate, to support the growing use of LH2 in heavy mobility, with an emphasis on sustainability and low emissions.
During the first period, two major tasks were undertaken: laying the groundwork for a generic Liquid Hydrogen Refueling Station and working on the test bench and its components. As a first step in the system functional analysis, a comprehensive assumption book was created and presented at the project Kick-Off Meeting, providing a framework for each partner’s work and highlighting their interdependencies. Accordingly, each work-package initiated its activities.
A large part of work was focused on the design of the test bench, its various components and their overall integration. In the meantime, the different concepts and data related to a generic station were developed to set the basis for its design, economics, political environment and safe operation.
• The cryogenic pump minimum requirements were defined while sub-systems design and quotation were performed with selected suppliers. Following iterative improvement, a design achieving theoretical performances beyond expectations was delivered and the manufacturing and assembly of the prototype was started, while preparing the integration of the pump into the test bench and the related test protocol
• For the loading line systems, final design for couplings integrating functions of quick connect, disconnect and brake away is being frozen after various iterations. Corresponding sanitation protocol was defined. Flexible hoses underwent their firsts tests and the prototype for the 1st test campaign is being manufactured. Flowmeters were selected after a technological benchmark and the RDCL design (reference instrument for calibration of flowmeters) has been upgraded and manufactured.
• Regarding Boil-Off Gas (BOG), preliminary simulations performed with in-house model provided the consortium with an initial BOG inventory. A qualitative selection of BOG management strategies was carried out and the preferred technologies for a generic Liquid Hydrogen Refuelling Station (LHRS) were chosen. In parallel, the BOG management system for the test bench was defined and its design and performances computed.
• Alongside the functional analysis performed that pre-defined the general architecture of the station, the test bench design was developped, the recirculating loop concept validated and its components are under contracting. Refinement of the planning and budget for the prototyping and demonstration phases is ongoing.
• Preliminary cost estimation of the LH2 station for maritime and aviation business cases has been completed, including a Class IV estimate and a deepdive of operational expenses. Initial assessments of the share of LH2 distribution in LCOH (Levelized Cost of Hydrogen) were conducted based on market maturity. A LHRS market analysis within the EU and worldwide has been performed and gives insights on future development of Liquid Hydrogen in heavy mobility. The study of policies at global and country levels led to the issuance of initial recommandations to foster LH2 development.
• Finally, the safety studies compiled a list of hazardous phenomena that will be used for safety engineering and fed the initial project safety plan which has been completed. The hazards identified have been studied with CFD simulations and the multi-phase CFD model of LH2 fuelling through the entire equipment of LHRS is ongoing. In parallel, existing Regulations Codes and Standards were reviewed with a structured methology to identify gaps to be addressed.
A large part of work was focused on the design of the test bench, its various components and their overall integration. In the meantime, the different concepts and data related to a generic station were developed to set the basis for its design, economics, political environment and safe operation.
• The cryogenic pump minimum requirements were defined while sub-systems design and quotation were performed with selected suppliers. Following iterative improvement, a design achieving theoretical performances beyond expectations was delivered and the manufacturing and assembly of the prototype was started, while preparing the integration of the pump into the test bench and the related test protocol
• For the loading line systems, final design for couplings integrating functions of quick connect, disconnect and brake away is being frozen after various iterations. Corresponding sanitation protocol was defined. Flexible hoses underwent their firsts tests and the prototype for the 1st test campaign is being manufactured. Flowmeters were selected after a technological benchmark and the RDCL design (reference instrument for calibration of flowmeters) has been upgraded and manufactured.
• Regarding Boil-Off Gas (BOG), preliminary simulations performed with in-house model provided the consortium with an initial BOG inventory. A qualitative selection of BOG management strategies was carried out and the preferred technologies for a generic Liquid Hydrogen Refuelling Station (LHRS) were chosen. In parallel, the BOG management system for the test bench was defined and its design and performances computed.
• Alongside the functional analysis performed that pre-defined the general architecture of the station, the test bench design was developped, the recirculating loop concept validated and its components are under contracting. Refinement of the planning and budget for the prototyping and demonstration phases is ongoing.
• Preliminary cost estimation of the LH2 station for maritime and aviation business cases has been completed, including a Class IV estimate and a deepdive of operational expenses. Initial assessments of the share of LH2 distribution in LCOH (Levelized Cost of Hydrogen) were conducted based on market maturity. A LHRS market analysis within the EU and worldwide has been performed and gives insights on future development of Liquid Hydrogen in heavy mobility. The study of policies at global and country levels led to the issuance of initial recommandations to foster LH2 development.
• Finally, the safety studies compiled a list of hazardous phenomena that will be used for safety engineering and fed the initial project safety plan which has been completed. The hazards identified have been studied with CFD simulations and the multi-phase CFD model of LH2 fuelling through the entire equipment of LHRS is ongoing. In parallel, existing Regulations Codes and Standards were reviewed with a structured methology to identify gaps to be addressed.
The project is developing a refuelling station for maritime, aviation and railroad applications, capable to deliver a never achieved flowrate (>5 TPH) with a high efficiency (>60%) cryogenic centrifugal pump and through a first of its kind loading line. The last consists of an architecture with a flexible hose allowing to reach the best compromise between insulation performance and design life and a Quick Connect Disconnect Coupling with self-sealing cryogenic valves capable of operating repeatably at 20K. Moreover, it is creating a protocol using efficiently GN2 for sanitation instead of GHe. The project is also maturing a BOG recovering system and will validate accurate analytical BOG prediction model and multiphase CFD simulation of the refuelling operations.
The first period of the project gave encouraging results towards those objectives. The pump flowrate appears achievable and the theoretical efficiency is beyond the target. The Quick Connect Disconnect Coupling is already under testing and the refuelling protocol using GN2 has been established and remains to be tested. The BOG estimations have converged and innovative solutions for the BOG recovering system have been selected.
The first period of the project gave encouraging results towards those objectives. The pump flowrate appears achievable and the theoretical efficiency is beyond the target. The Quick Connect Disconnect Coupling is already under testing and the refuelling protocol using GN2 has been established and remains to be tested. The BOG estimations have converged and innovative solutions for the BOG recovering system have been selected.