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Hydrogen Energy Technology

Hydrogen Reconversion
Course Renewable Energies 2011/12

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Hydrogen Energy Technology

Hydrogen Reconversion - Content of the lecture


1.
1.1
1.2
1.3
2.
3.
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5.
5.1
5.2
6.
7.
8.

Introduction
The hydrogen energy system overview
The meaning of the hydrogen energy system
The Laboratory for Integrated Energy Systems - main parts of the system
Characteristics of hydrogen
Thermal properties of ideal gases summary
Combustion of hydrogen
Low heating value LHVH2 and high heating value HHVH2 of hydrogen
Energy density of fuels
Heating value of gas mixtures
Minimal air consumption Lmin
Air fuel ratio
Low heating value of the air fuel mixture LHVAFM
Volumetric change at the reaction
Methane number of gases
Catalytic combustion of hydrogen
Catalytic burners
Use of catalytic burners in boilers
Hydrogen as a fuel for internal combustion engines (ICE)
Hydrogen as a fuel for gas turbines
Safe use of hydrogen

Dipl.-Ing. (FH) Christian Sponholz

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1.1 Hydrogen Energy System - Overview


Renewable
Energies
Sun, Wind, Water

Photovoltaic
Installation
Windmill
Water Power Station

Electrical
Energy

Electrolyseur

Hydrogen prod.
from biomass
Electrical Energy

Fuel Cell
Power and Heat
Cogeneraton Plant

Hydrogen
Hydrogen Storage System
Hydrogen Reconversion

Thermal Energy

Boiler, Cooker,
Burner

Mechanical Energy

Gas Turbine,
Combustion Engine
Hydrogen Energy Reconversion

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

1.2 Hydrogen Energy System - Meaning


 unlimited production of hydrogen by electrolysis (electrical energy
only from renewable energies) or biomass
 reduction of emissions : CO2, CO, HC, NOX, SOX
 substitution of fossil sources of energy - fossil sources of energy are
not unlimited available
 high efficiency is possible (e.g. fuel cell, heat and power cogeneration plants)

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

1.2 Hydrogen Energy System - Meaning


 safety of a hydrogen system is comparable with a natural gas system
 hydrogen infrastructure is actual not present
o field tests and projects: ARGEMUC (Munich Airport Project),
CUTE (Clean Urban Transport for Europe), CEP (Clean-EnergyPartnership)
o hydrogen pipeline systems for chemical industry:
Linde (Leuna) 80 km, Air Liquide (Ruhr area) 240 km, also in
Belgium, France, USA, Canda
 island systems for not grid connected areas are in developement
(wind-hydrogen, PV-hydrogen)
 hydrogen storage systems for mobile applications are available
Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

1.2 Hydrogen Energy System - Meaning

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

1.2 Hydrogen Energy System - Meaning

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

1.3 Laboratory for Integrated Energy Systems

Dipl.-Ing. (FH) Christian Sponholz

100 kW windmill
Ventis 20-100

10 kWp photovoltaik
installation

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1.3 Laboratory for Integrated Energy Systems

Electrolysis station with storage tank for compressed gaseous hydrogen

Dipl.-Ing. (FH) Christian Sponholz

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1.3 Laboratory for Integrated Energy Systems

350 bar compressor (Hofer) for hydrogen

20 kW alcaline electrolyser (ELWATEC)

Dipl.-Ing. (FH) Christian Sponholz

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1.3 Laboratory for Integrated Energy Systems

450 W experimental fuel cell from ZSW

Dipl.-Ing. (FH) Christian Sponholz

2 kW power supply system with Ballard NEXA fuel cells

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1.3 Laboratory for Integrated Energy Systems

20 kW catalytic hydrogen burner (FSE) for a heating boiler

Dipl.-Ing. (FH) Christian Sponholz

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1.3 Laboratory for Integrated Energy Systems

Experimental car with hydrogen engine (31 kW)

Dipl.-Ing. (FH) Christian Sponholz

Cogeneration plant for hydrogen-natural gas


mixtures (30 kW)

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2. Characteristics of hydrogen
hydrogen

petrol

0,02

0,24

min. ignition energy in air

mJ

ignition limits in air

Vol-%

4 - 75

18

laminar burning velocity (st.)

cm/s

ca. 190

ca. 40

stoichiometric mixture in air

Vol-%

29,53

1,76

heating value of the mixture


(st.)

kJ/m3

3240

3835

Dipl.-Ing. (FH) Christian Sponholz

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2. Characteristics of hydrogen

Dipl.-Ing. (FH) Christian Sponholz

Flame temperatures of hydrogen-air mixtures

Source: Winter, Nietsch: Hydrogen as


an energy carrier, Springer Verlag 1988

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Hydrogen Energy Technology

2. Characteristics of hydrogen

Dipl.-Ing. (FH) Christian Sponholz

Ignition limits of
hydrogen and methane
and there mixtures

Source:
Winter, Nietsch: Hydrogen
as an energy carrier,
Springer Verlag 1988

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Hydrogen Energy Technology

2. Characteristics of hydrogen

Minimal ignition energy for H2-air and CH4-air mixtures

Source: Winter, Nietsch: Hydrogen as


an energy carrier, Springer Verlag 1988

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Hydrogen Energy Technology

2. Characteristics of hydrogen

Dipl.-Ing. (FH) Christian Sponholz

Laminar burning velocity of hydrogen

Source: Winter, Nietsch: Hydrogen as


an energy carrier, Springer Verlag 1988

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Hydrogen Energy Technology

2. Characteristics of hydrogen

Dipl.-Ing. (FH) Christian Sponholz

Laminar flame velocity of different combustible gases

Source: Winter, Nietsch: Hydrogen as


an energy carrier, Springer Verlag 1988

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Hydrogen Energy Technology

3. Thermal properties of ideal gases


standard conditions of gases
two standard conditions (Normal Temperature and Pressure) :
Physical standard conditions (DIN 1343)
p = 1,0133 bar
T = 0C = 273,15 K
Technical standard conditions (DIN 1945)
p = 0,981 bar
T = 20C = 293,15 K
Other standard conditions are possible e.g.
p = 1,013 bar
T = 0C = 273,15 K
Ideal Gas : molar volume Vm = 22,414 m3/kmol
Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

4.2 Energy density of fuels

Source : VDI Berichte 1201:


W.Strobl, E.Heck;
Wasserstoff und mgliche
Zwischenschritte

Dipl.-Ing. (FH) Christian Sponholz

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4.2 Energy density of fuels

Hydrogen Energy Technology

state of
aggregation

: gas

volume

: 2 x 60 dm3

max. pressure : 200 bar


max. capacity : 24 m3 NTP
material

: steel wrapped
with fibres
(Aramid)

Storage unit for hydrogen in an experimental car

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

4.3 Low Heating Value LHV and High Heating


Value HHV of gas mixtures
Low Heating Value : used heat from the combustion, if the exhaust
gases have the the same temperature like the fuel and air, the water
in the exhaust gas is only vapour
High Heating Value : used heat from the combustion, if the exhaust
gases have the the same temperature like the fuel and air, the water
vapour in the exhaust gas is completely condensed to liquid water
for gases:
CO + H2 + CHn + CmHm + H2S + O2 + SO2 + H2O = 1 [m3/m3]
LHV = 12600 CO + 10790 H2 + 35800 CH4 + 64300 C2H2 + ... [kJ/m3]
HHV = 12600 CO + 12800 H2 + 39900 CH4 + 70400 C2H2 + ... [kJ/m3]
for solid or liquid fuels:
c + h + s + o + n + w + a = 1 [kg/kg]
LHV = HHV 2500 kJ/kg * (9 h + w)

Dipl.-Ing. (FH) Christian Sponholz

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mole-ratio [-]

Hydrogen Energy Technology

4.7 Volumetric change at the reaction for


hydrogen-air-combustion

internal mixture formation


external mixture formation

air-fuel-ratio [-]

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Hydrogen Energy Technology

5. Catalytic combustion of hydrogen

Catalytic heater at FH Stralsund


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Hydrogen Energy Technology

5. Catalytic combustion of hydrogen

Air

Water vapour

Hydrogen

Porous catalyst
Schematic model of a hydrogen burner
Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

5.1 Catalytic burners

Burner stick

Dipl.-Ing. (FH) Christian Sponholz

length 8 cm, diameter 1,7 cm


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5.1 Catalytic burners

Porous surface of the burner stick


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Hydrogen Energy Technology

5.1 Catalytic burners

Characteristics of the catalytic burner for hydrogen:


Simple and robust design
Low combustion temperature (max. 800C) low NOX-emissions
Complete catalytic combustion at temperatures higher then 500C
No pre-mixing of hydrogen and air no explosive mixture
Gap of the pores : 10 m (extinguishing distance of H2 : 64 m, no
backfiering problems)
 Material : mainly Nickel, doped with Platinum







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Hydrogen Energy Technology

5.1 Catalytic burners experimental results

Surface temperature of a burner stick at low power


Dipl.-Ing. (FH) Christian Sponholz

Source : T. Panten Labor STL/STM

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5.1 Catalytic burners experimental results

Temperature in the surroundings of a burner stick


Dipl.-Ing. (FH) Christian Sponholz

Source : T. Panten Labor STL/STM

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Hydrogen Energy Technology

5.1 Catalytic burners experimental results

Airflow around the (single) burner stick


Dipl.-Ing. (FH) Christian Sponholz

Source : T. Panten Labor STL/STM


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Hydrogen Energy Technology

5.1 Catalytic burners experimental results

Airflow around the (single) burner stick


Dipl.-Ing. (FH) Christian Sponholz

Source : T. Panten Labor STL/STM


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5.2 Use of catalytic burners in boilers

Catalytic burner for hydrogen in operation outside of the combustion chamber


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Hydrogen Energy Technology

5.2 Use of catalytic burners in boilers

Schematic model of the condensing boiler for hydrogen


Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

5.2 Use of catalytic burners in boilers


Condensing boiler
Manufacturer
Type
Year of production
Heat power output
Catalytic Burner
Manufacturer
Heat power output
H2-quality
H2-consumption
Device inlet pressure
Burner inlet pressure
O2-concentration
in dry exhaust gas
Max. temperature

Dipl.-Ing. (FH) Christian Sponholz

: Buderus Heiztechnik GmbH


: SB 305 U-39
: 1995
: 39 kW (using natural gas)

: Fraunhofer Institut for Solar Energy Systems


: 21 kW
: > 99,0 %
: 120 l/min (standard conditions)
: 3 - 5 bar
: 18 - 20 mbar
: 13 - 15 Vol-%
: ca. 800C (at the surface of the burner)
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5.2 Use of catalytic burners in boilers parts of


the burner system

Dipl.-Ing. (FH) Christian Sponholz

1 - Ignition coil
2 - Air inlet control
3 - Gas valves
4 - Cables for thermocouples
5 - Pressure control unit
6 - Air deficiency switch
7 - Pressure control unit with safety valve
8 - Fan (radial)
9 - Air filter cover
10 - Automatic starter unit
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5.2 Use of catalytic burners in boilers operating


behaviour

Start behaviour of a catalytic hydrogen burner


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Hydrogen Energy Technology

5.2 Use of catalytic burners in boilers operating


behaviour

Long time measurement on a catalytic hydrogen burner


Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

5.2 Use of catalytic burners in boilers operating


behaviour

Long time measurement on a catalytic hydrogen burner calculation example


Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

5.2 Use of catalytic burners in boilers safety system


1. Monitoring the combustion
 Measuring of the temperature in the combustion chamber (3 points)
 Measuring of a sudden temperature changes
2. Hydrogen sensor in the exhaust gas channel detects unburnt
hydrogen
3. Hydrogen sensor over the boiler detects leakages of hydrogen
4. Solenoid valves closes the hydrogen supply immediatly if a failure
appeares

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

5.2 Use of catalytic burners in boilers (cookers)

Autarchic cooker with catalytic hydrogen burner


Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion


engines (ICE)

Contents:








Introduction
External mixture formation for hydrogen operated engines
Project : Experimental hydrogen car Ford Escort
Project : External hydrogen mixture formation for diesel engines
Internal mixture formation for hydrogen
Project : Internal mixture formation for hydrogen in a combustion
chamber
Summary

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)








production of hydrogen by electrolysis (electrical energy only from


renewable energies)
substitution of fossil sources of energy
reduction of emissions : CO2, CO, HC
spark ignition and self ignition is possible
external and internal mixture formation ist possible
high laminar burning velocity
wide ignition limits (in air)




specific mixture formation and combustion for hydrogen


safety systems are necessary

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

characteristics of hydrogen

unit

hydrogen

petrol

min. ignition energy in air

mJ

0,02

0,24

Vol-%

4 - 75

18

laminar burning velocity (st.)

cm/s

ca. 190

ca. 40

stoichiometric mixture in air

Vol-%

29,53

1,76

heating value of the mixture (st.)

kJ/m3

3240

3835

ignition limits in air

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

 status up until now is the use of gaseous hydrogen in engines


 liquid hydrogen only for storage - low temperatures cause problems
with the material of valves, pipes, pumps
 internal mixture formation is in developement (until now only in
laboratory experiments)
 spark ignition of hydrogen is without big problems, only water
deposits on spark plugs during cold start are problematic
 self ignition until now only in laboratory experiments
 external mixture formation is ready for serial production

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

Hydrogen operated Otto-engines - state of development 




intensive research and developement for hydrogen operated Ottoengines started in germany in the 1970s
most important german automobile manufacturers with selfdeveloped engines are :
BMW (750hL, 12-cylinder Otto-engine, VH=5,4 dm3, P=150 kW)
Daimler-Benz 1985-1988 (MB310 Truck, 4-cylinder Otto-engine,
VH=2,3 dm3, P=75 kW)
MAN (SL202 Bus, 6-cylinder Otto-engine, VH=12 dm3, P=140
kW)

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

Fig. : BMW 750 hL (Photo : BMW AG)

Fig. : 6-cylinder Otto-engine for Hydrogen


on the testbed (Photo : BMW AG)

Fig. : MAN-Bus with H2-Otto engine (Photo : MAN AG)

Dipl.-Ing. (FH) Christian Sponholz

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6. Hydrogen as a fuel for internal combustion engines


(ICE)

Hydrogen Energy Technology

Photos : BMW AG

Dipl.-Ing. (FH) Christian Sponholz

BMW Hydrogen 7 (12 Cylinder), year 2006

Displacement: 6 dm3

Power: 191 kW

Torque: 390 Nm at 4300 rpm

Range: 200 km with H2 + 500 km with petrol

External mixture formation with:


> 2 at partial load (for Hydrogen)
= 1 at full load (for Hydrogen)
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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

External mixture formation for combustion engines


external mixture formation

single point mixture formation

naturally aspirated engine

gas mixer

Dipl.-Ing. (FH) Christian Sponholz

mixture-charged engine

single point injection

multi point mixture formation

naturally aspirated engine

air-charged engine

sequential multipoint injection

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Hydrogen as fuel for Otto-engines - problems of mixture formation -






self-ignition of the mixture during the intake stroke by :


hot spots in the cylinder head
hot exhaust gases
glowing oil particles in the combustion chamber
backfiering into the intake pipes during the intake stroke
abnormal combustion (knocking problems)
NOX-emissions
lower power output by comparison to petrol

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

Measures for the elimination of the problems

 use of lean mixtures (


1,8)
decreasing of the combustion temperatures (prevent
NOX-emission and self ignition)
cooling of hot spots in the cylinder head (prevent self
ignition)
increasing of the ignition energy (prevent self ignition and
abnormal combustion )
but it decreases the power output
 avoidance of hydrogen accumulation in the intake manifold
(prevent backfiering)

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

Requirements to the mixture formation unit

supply to the engine with lean mixtures at 1,8


sequential multipoint injection for each cylinder only at the
intake stroke
prevention of leakages in the injectors

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

External mixture formation for hydrogen

Fig.:
cross-section through the
cylinder head of a BMW bifuel engine with intake
manifold (left); gasoline
injection valve (top); hydrogen
injection valve (bottom)

Picture: BMW

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)

External mixture formation for hydrogen

Fig.:
cross-section of the hydrogen
engine with fuel injection valve

MAN H2866 UH
6-cylinde-4-stroke cycle
12 litres, 140 kW

Picture: MAN
Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Project : Experimental hydrogen car Ford Escort

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Storage unit for hydrogen

Dipl.-Ing. (FH) Christian Sponholz

state of
Aggregation

: gas

volume

: 2 x 60 dm3

max. pressure : 200 bar


max. capacity : 24 m3 NTP
material

: steel wrapped with


fibres (Aramid)

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Safety system

 two solenoid valves close the main hydrogen pipe in case :


- if one of three gas sensors detects hydrogen
- if a mechanical shock is detected by a special sensor
- if voltage is not present
- if the crankshaft not turns

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Gas detection system

Fig.: sensor for H2 over the driver seat

Dipl.-Ing. (FH) Christian Sponholz

Fig.: sensor for H2 over the storage unit

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Hydrogen gas system in the experimental car

Dipl.-Ing. (FH) Christian Sponholz

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Mixture formation unit for the experimental engine at FH Stralsund

Fig.: mixtur formation unit for hydrogen

Dipl.-Ing. (FH) Christian Sponholz

Fig.: hydrogen injector

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Mixture formation unit for the experimental engine at FH Stralsund

Fig.: hydrogen injector


Dipl.-Ing. (FH) Christian Sponholz

Fig.: H2-control valve


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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Mixture formation unit for the experimental engine at FH Stralsund

Fig.: H2-experimental engine

Dipl.-Ing. (FH) Christian Sponholz

Fig.: inlet pressure switch

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Experimental engine at FH Stralsund

Project : Experimental hydrogen car Ford Escort 1996/1997


Engine








manufacturer
type
dispacement
compression ratio
ignition timing
used air / fuel ratio
max. power

Dipl.-Ing. (FH) Christian Sponholz

: Ford
: 4 cylinder - 4 stroke Otto engine
: 1400 cm3
: 9,5 : 1
: 10 BTDC
: 1,8 - 3,0
: 18 kW (n = 3900 min-1);
(previously 55 kW with petrol)

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Experimental engine at FH Stralsund

Project : Experimental hydrogen car Ford Escort 2001/2002/2003


-

new free progammable engine control unit MOTEC M4


adaptation of new and additional sensors : engine temperatur, intake
air temperatur, camshaft position
adaption of wide band lambda sensor Bosch LSM 11
engine fine tuning (dynamometer Bosch FLA 206)
emission-analysis (Horiba EXSA 1500)
combustion pressure indication and work process of the engine

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Experimental engine at FH Stralsund
Project : Experimental hydrogen car Ford Escort 2001/2002/2003
Results after optimization


max. power





efficiency e
ignition timing
used air / fuel ratio

Dipl.-Ing. (FH) Christian Sponholz

: 31 kW (n = 5000 min-1);
(previously 55 kW with petrol)
: max. 0,39
: 0 - 18 BTDC
: 1,8 - 2,0

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Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Engine Control Unit

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Sensors for combustion pressure indication and work process of the
engine

TC

CPS
Fig.: crank angle sensor

TC

Fig.:cylinder pressure sensor CPS with spark plug adaptor and


thermocouples TC for intake air and exhaust gas temperature

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Pressure cycle in cylinder

pZ(VZ) at different ignition timings, n=2000 min-1, TP=40%, =1,8 (ZZP=IT) (TP=throttle position)
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Knocking problems

pZ(VZ) at different ignition timings, n=2000 min-1, TP=40%, =1,8 (ZZP=IT) (TP=throttle position)
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Knocking problems

Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Efficiency and Torque

Md(IT), e(IT) at different ignition timings, n=2000 min-1, TP=40%, =1,8, (ZZP=IT) (TP=throttle position)
Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Temperature and NOX-Emissions

Tproc(), Tex(), NOX() at different air-fuel-ratios, n=2000 min-1,Md=30 Nm, IT=5 BTDC
Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Torque Throttle Position

Torque Md at different engine speed and throttle position (DK=TP=throttle position)


Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Efficiency

Efficiency e at different engine speed and throttle position (DK=TP=throttle position)


Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Power Air Fuel Ratio at WOT

Tproc(), Tex(), NOX() at different air-fuel-ratios, n=2000 min-1,Md=30 Nm, IT=5 BTDC, WOT=Wide Open Throttle
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Efficiency

Black: Efficiency e at different engine speed and load (DK=TP=throttle position - load)
Red: Efficiency e at different engine speed and load equivalent (DK* - load equivalent)
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Project : External hydrogen mixture formation for diesel engines

Fischer-Panda AGT 30.000 PMS


Engine: YANMAR 4JH3E
Displacement: 1995 cm
Rated power: 35 kW (at 3000 min-1)

Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Mixture formation unit

Dipl.-Ing. (FH) Christian Sponholz

H2+Air

Air

Exhaust gas

1 gas valve
2 safety valve
3 pressure regulator
4 max. pressure control switch
5 safety valve
6 min. pressure control switch
7 mass flow controller
8 air filter
9 hydrogen sensor
10 mixing chamber
11 pressure control switch backfiering

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Efficiency

Efficiency for Diesel- and Dual-Fuel-Operation depending on diesel fuel mass flow
Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
NOX-Emissions

NOX-emissions for Diesel- and Dual-Fuel-Operation depending on power output


Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Internal mixture formation for combustion engines

internal mixture formation

naturally aspirated engine

charged engine

exhaust turbocharger

mechanical charger

high pressure injection

common-rail

Dipl.-Ing. (FH) Christian Sponholz

unit injection system

injection pump

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Project : Internal mixture formation for hydrogen in a combustion chamber

main responsible persons:


Prof. Dr.-Ing. W. Beckmann
Dipl.-Ing. J. Brcker
carried out from 1996 - 2001 at FH Stralsund
engineering and design of a high pressure hydrogen injector
numerical simulation of the injection
testing the injector in a combustion chamber with constant volume

Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Testbed: constant volume combustion chamber
A Data acquisition system
MUSYCS
B Servo amplifier
C Exhaust gas analyzer
D Needle lift sensor
E Servo valve
F Hydraulic system
G Injection valve
H Combustion chamber
J Hydrogen system
K Air system and nitrogen purge
system
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Testbed : combustion chamber with constant volume for internal
mixture formation

Research
project at FH
Stralsund:
Prof. Dr.-Ing. W.
Beckmann,
Dipl.-Ing. J.
Brcker

Dipl.-Ing. (FH) Christian Sponholz

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understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Combustion chamber with constant volume for internal mixture formation
Indices :
SN
pu,Tu

(u) - ambient conditions


(L) - conditions in the gas pipe

LHVH2,H2(L),pH2(L),
TH2(L)

(Bk) - cond. in the comb. chamber


conditions 1 = intake air conditions
conditions 2 = process conditions

V = const.

cond. 1
pAir(Bk)
TAir(Bk)
Air(Bk)
mAir(Bk)

cond. 2
p(Bk)=f(t)
T(Bk)=f(t)
m(Bk)=f(t)
mEx-gas(Bk)

Research
project at FH
Stralsund:
Prof. Dr.-Ing. W.
Beckmann,
Dipl.-Ing. J.
Brcker

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Behaviour of the high pressure injector

Research
project at FH
Stralsund:
Prof. Dr.-Ing. W.
Beckmann,
Dipl.-Ing. J.
Brcker

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Combustion process in the constant volume combustion chamber

Research
project at FH
Stralsund:
Prof. Dr.-Ing. W.
Beckmann,
Dipl.-Ing. J.
Brcker

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Influence of the air-fuel-ratio on the combustion pressure profil

Research
project at FH
Stralsund:
Prof. Dr.-Ing. W.
Beckmann,
Dipl.-Ing. J.
Brcker

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Influence of the ignition timing on the combustion pressure profil

Research
project at FH
Stralsund:
Prof. Dr.-Ing. W.
Beckmann,
Dipl.-Ing. J.
Brcker

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Summary

internal combustion engines for hydrogen from some manufacturers


are ready for serial production
state of development is the engine with external mixture formation and
spark ignition
lower power output compared to petrol engines is the disadvantage
further developments with internal mixture formation and
supercharged engines for more power output are possible
improved hydrogen storage systems are necessary
to build up a hydrogen infrastructure is necessary
fuel cells with a higher efficiency then combustion engines can be a
alternative for the future

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
Emissions of a hydrogen engine

Engine: MAN H 2866 UH


Picture: MAN
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

6. Hydrogen as a fuel for internal combustion engines


(ICE)
NOX-emissions of different hydrogen engine types

Picture: Hydrogen as an
energy carrier
Winter, Nitsch; 1988
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)

German Russian cooperation project Cryoplane


Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Source: EADS

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)
German Russian cooperation project Cryoplane participants :
Tupolev Moscow
Kusnetsov Samara
Daimler Chrysler

MAN
Max-Planck-Institut
Messer Griesheim

Allied Signal Aerospace

Uhde

Linde

Lufthansa

Airport Munich

Drger

BAM

Fachhochschule Aachen

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)

Overview :
German Russian cooperation project Cryoplane started 1990
Target : use of cryogenic fuels (LNG, LH2) for aircraft engines
1990 1992 analysis of feasibility
Developement of components for the fuel system and for the aircraft
engines
 Main part developemet of low-pollutant combustion chambers for
hydrogen











Latest activities :
Tests with special developed combustion chambers for hydrogen
Operation of gas turbine with hydrogen on a testbed
Planning of a hydrogen operated airplane

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)

Air-H2-mixing chamber for


gas turbine GTCP 36-300
Source: Fachhochschule
Aachen

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)

NOX-emissions depending
on load
Source: Fachhochschule
Aachen
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)

Hydrogen injection nozzles


in the combustion chamber
NK 88
Source: H2-Cryoplane,
Airbus

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)

Gas turbine P&W 4000


series
Source: H2-Cryoplane,
Airbus
Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)

NOX-Emissions of gas
turbines
Source: H2-Cryoplane,
Airbus

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for gas turbines


Hydrogen for aircraft engines (gas turbines)
Advantage of liquid hydrogen as fuel for airplanes :

Storage of 3 times more fuel is possible or


Increasing 3 times the payload

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for (stationary) gas turbines

Source: Norm Shilling,


Robert M. Jones
Process Power Plants
GE Power Systems

Dipl.-Ing. (FH) Christian Sponholz

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for (stationary) gas turbines

Dipl.-Ing. (FH) Christian Sponholz

Source: Norm Shilling,


Robert M. Jones
Process Power Plants
GE Power Systems

praxis verstehen chancen erkennen zukunft gestalten


understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for (stationary) gas turbines

Dipl.-Ing. (FH) Christian Sponholz

Source: Michel Moliere


GE Energy

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understanding reality facing challenges creating future

Hydrogen Energy Technology

7. Hydrogen as a fuel for (stationary) gas turbines

Dipl.-Ing. (FH) Christian Sponholz

Source: Michel Moliere


GE Energy

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understanding reality facing challenges creating future

8. Safe use of hydrogen - protection against explosion


1. Are flammable substances existing ?

No

No protection against explosion necessary !

No

No protection against explosion necessary !

No

No protection against explosion necessary !

Yes

No further protection against explosion necessary !

Yes
2. Is an explosive mixture by dissemination in air possible ?

Hydrogen Energy Technology

Yes
3. Analysis of quantities and sources of explosive atmosphere necessary !
4. Is a dangerous explosive atmosphere possible ?
Yes
5. Protection against explosion necessary !
6. Restrict the formation of an explosive atmosphere as far as possible !
7. Is the formation of an dangerous explosive atmosphere restricted ?
No
8. Further protection against explosion necessary !
A dangerous explosive atmosphere is existing by gases and vapours:
permanent, long-term : Zone 0

at times : Zone 1

rarely, short-term : Zone 2

9. Prevention of ignition sources :


at failure-free operation
at often failures
at rarely failures

at failure-free operation
at often failures

at failure-free operation

10. Precautions by design, which limits the effects of an explosion to a safe degree.
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understanding reality facing challenges creating future

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