Periodic Reporting for period 2 - COSMHYC XL (COmbined hybrid Solution of Metal HYdride and mechanical Compressors for eXtra Large scale hydrogen refuelling stations)
Reporting period: 2020-07-01 to 2021-12-31
In parallel to this work, the consortium completed the former COSMHYC project by conducting long term testing of a prototype of lower capacity (100 kg/day) based on the same hydride principle. During the second period of the COSMHYC XL project, the results and technical know-how generated within the COSMHYC tests, were used to review and improve the conception and design of the new prototype which is conceived to demonstrate a baseload capacity of 200 kg/day, allowing to reach 950 bar for refueling hydrogen at 700 bar.
During the second period of the project, the consortium focused on following aspects:
- The impacts of 5 possible pollutants (N2, CO, CO2, O2 and H20) on the metal hydrides were studied in a comprehensive way. The results allow to better master the manufacturing process of hydrides and to ensure reliable performances operation of the compressive reactors. Based on these results, the composition of the hydrides was revised.
- The selection of rare earth free metal hydrides is under review to allow performant compression from ˜1 to 500 bar in 3 compression stage. Also the designs of the reactors were reviewed for optimization. Partner MAHYTEC well advanced the production of the metal hydrides and the manufacturing of the reactors. Each manufactured reactor undergoes individual certification.
- The metal hydrides reactors will be integrated in the innovative compressor to be commissioned during period 3 on a test site prepared by partner EIFER. All necessary safety studies and pre-certification were completed to be able to conduct long term tests in 2022.
- During period 2, EIFER also finalised the design of the innovative hydride compressor, completing the large-scale oriented system integration system, incl. control, monitoring and thermal systems.
- Development also happened fast on the mechanical compressor of partner NEL. The new mechanical compressor design benefits from the learnings gained within the COSMHYC project. It was built and submitted to comprehensive iterative testing and development phases during the second period of the project. The expected performances could be demonstrated. More over the concept designs for dual-crank compressor(s) were developed to reach 120kg/h (2-stage) and 240kg/h in duplex configuration.
The consortium partners will now commission the new metal hydride compressor and conduct long term test following a test protocol conceive for simulating its operation in combination with the mechanical compressor.
Also the performances and flow rates of the mechanical compressor is significantly improved. COSMHYC has already enabled significant improvements of life-time, efficiency and flow rate, aiming at capacities of 120kg/h thanks to innovative system integration concepts. The ambition to scale up-capacity while maintaining the same time the lifetime and efficiency levels in COSMHYC has been demonstrated during the second period of the project. The new prototype also operates with very low noise and the whole system remains under the 60dB.
The joint efforts on two compression technologies and on integrating them in a modular and flexible compression solution will allow flow rates will have a significant positive impact on the future costs of refuelling stations. Thanks to the hydride solution, the electricity consumption of the COSMHYC XL hybrid compressor will lower electricity consumption and to strongly reduce CAPEX: a reduction of 50% is expected compared to the current CAPEX of non-mechanical compressors.