Testbed Leader: Clean Technology Systems H2
Brugnera (PN) – Viale Lino Zanussi 1 – 33070, Italy
Director (or representative): Federica Zagarella (f.zagarella@ctsh2.com)
Project Description
The testbed focuses on validating and implementing a small, potentially distributed hydrogen refuelling station with onsite renewable H2 production. The station will produce up to 2 tons of renewable H2 annually, powered by either a small hydroelectric station or a photovoltaic plant. The H2 will be produced using an AEM electrolyser (35 bar max pressure), ensuring 99.999% purity, and stored in a 2324-liter system. The electrolyser type will depend on the power source: AEM for variable solar power (60 kW) and AWE for continuous solar power (1 MW). Rainwater collected from the cabinet roof will be used in the electrolytic process. After compression to 300 bar, H2 will be stored and used to refuel vehicles according to SAEJ2601: 2010 standards, reaching up to 350 bar in two phases. Additionally, a Fuel Cell (HFC) will provide up to 5kW of energy for small devices, lighting, or self-supplying the station. An industrial research activity will also focus on developing a high-pressure demo electrolyser that supplies H2 at 350 bar without compression.
Impact and Benefits
CTS H2 S.r.l. will develop the first demo modular and transportable HRS powered by renewable energy source, in circular economy regime, and in cogeneration state, serving Fuel Cell Electric Vehicles (FCEVs) along the north Adriatic corridor. The HRS will be located in a “plug and play” container that can be moved by truck transport; depending on the power plant size, more modular containers can be moved and installed.
Once fully operational, the system will be able to fuel buses for running 50 thousand kilometres yearly with a production of 6000kg of hydrogen implying the possibility to use at the same time 30000 kW of thermal energy and 7000 kW of electricity.
The system will be able to sequestrate 56.600 kg of CO2 and release 30000 Nmc of oxygen, corresponding to the effect of a 1.1 hectare of forest per year.
Thanks to the fuel cell, each kWh of electrical energy produced from hydrogen will depurate 250 litres of air per hour.
Key Metrics
- AEM or SPECIAL AWE electrolyser (35 bar maximum pressure) with 99,999% purity;
- inertial buffer tank;
- 2324 litres cylinder rack as storage tank;
- Filling process (compression to 350 bar) in 2 phases;
- Fuel Cell (5kW);
- Production of carrier to fuel buses for potentially running 50’000 kilometres;
- A small innovative AES electrolyser on company test bench for the H2 production in high pressure.
Current Plans
The testbed project is in the preliminary design phase. CTS H2 S.r.l. is in discussions with potential stakeholders to identify a suitable location and renewable energy source (RES). However, progress is slow due to several challenges: finding stakeholders to invest in fuel cell electric vehicles (FCEVs), identifying a strategic site for hydrogen-integrated heavy vehicles with expansion potential, locating a site near renewable plants (the initial hydroelectric plant has logistical and authorization issues), and securing further investments and a suitable site for the hydrogen refuelling station (HRS). Additionally, the project faces budget reductions despite significant efforts to engage stakeholders.
Progress Highlights
This project builds on 18 years of experience in the hydrogen sector by CTS H2. The goal is to create an innovative, modular, and transportable hydrogen refueling station (HRS) that efficiently produces green hydrogen using renewable energy sources (RES) through electrolysis.
Key Features
Modularity: The HRS will be made of easy-to-assemble modules in mini-containers, allowing for rapid installation and flexible configurations.
Transportability: The modules will be designed for easy movement on standard vehicles, even to remote locations.
Efficiency: The system will maximize energy efficiency, from hydrogen production to storage and distribution, using IoT technologies to optimize self-consumption and reduce O&M costs.
Green Hydrogen: 100% of the hydrogen produced will come from renewable sources like solar or wind power.
Cogeneration: The system can be equipped for cogeneration, producing both electric and thermal energy by using waste heat from electrolysis.
Power-to-Power: The system can operate in power-to-power mode, using hydrogen-generated electricity for auxiliary functions and grid balancing.
High-Pressure Storage: Hydrogen will be stored in high-pressure tanks for greater energy density and autonomy.
New Electrolysis Technology: A new high-efficiency electrolysis technology will be tested to produce high-pressure hydrogen directly, eliminating the need for a compressor, reducing costs, and extending system life.
This testbed will provide an innovative, sustainable, and flexible solution for producing and distributing green hydrogen for heavy vehicles, suitable for both private and public HRSs.
Future Plans
Once clarified the budget situation and obtained and extra financing, the testbed implementation could proceed.