COSMHYC XL started with an economic analysis confirming that the envisaged hybrid compression system, allowing for a whole range of configurations, is well adapted for different large-scale Fuel Cell transport applications (e.g. rigid trucks, semi-trailer tractors, city bus, regional trains). Technical and economic requirements were set, with the contribution of an advisory committee including experts and end-users, and integrated in the design of the different components of the system as well as in the large-scale oriented system integration. Comprehensive technical activities were then conducted to develop and build the metal hydride compressor and the mechanical compressor prototypes, with all their components.
The new designed dual-crank mechanical compressor, including all balance of plant components, was build and submitted to more than 2500 h of successful tests, corresponding to more than 100 million of cycles. The tests demonstrated that capacities of 120kg/h (2-stage) and 240kg/h in duplex configuration can be reached, while an economic assessment demonstrated reduction of costs of manufacturing.
For the metal hydride compressor, three new hydrides without rare earths where selected for three stages allowing compression from 2 & 5 bar to 450 bar. A comprehensive study on degradation of such materials in case of pollutants (N2, CO, CO2, O2 and H20) allowed to better master the manufacturing process of hydrides and to ensure reliable operation of the compressive reactors. A long phase of technical development followed, enabling to build the metal hydrides compressive reactors. The metal hydride compressor was built, including its gas management system, its thermal management unit, the overall electric integration, the control and monitoring system, the safety management system and the outdoor containerisation. The metal hydride compressor prototype was successfully built at scale and certified. After successful TÜV approval of the full prototype, over 1000h of successful tests could be achieved, without visible degradation. Thus, major improvement in the overall reliability of the system integration & control was achieved, validating low O&M costs. In addition, a feasibility study allowed to demonstrate that electricity consumption can be reduced down to < 2 kWh/kg thanks to coupling with heat pumps.
Finally, the COSMHYC XL compression concept and its components (innovative metal hydride compressor and new dual crank mechanical compressor) is validated at TRL5 and the feasibility study shows its scalability to 2 t/day or more, with the possibility to meet larger peak demand up to 120 kg/h, depending on uses cases.
The testing activities offered the opportunity of presenting the prototypes to potential customers. Beyond site visits, the final webinar allowed detailed presentation of the results to a wide range of experts and stakeholders, from components suppliers to equipment and vehicles manufacturers. These dissemination activities allowed to confirmed the interest of the hydrogen community and the need for new compression solution This market traction supports the strong willingness of the partners to transform the project results into commercial products, following the path defined in the final exploitation roadmap of the project.
