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Efficient Chillers for Hydrogen Pre-cooling at Heavy-Duty Hydrogen Fueling Stations


d.      Efficient Chillers for Hydrogen Pre-cooling at Heavy-Duty Hydrogen Fueling Stations

This subtopic solicits proposals for R&D of novel concepts that will allow for maximum hydrogen refueling of medium- and heavy-duty (MD/HD) vehicles compared with traditional fuel routes.


Interest in the use of fuel cells onboard MD/HD vehicles is growing rapidly, due to their potential to enable high-power operation, long range, and zero emissions. Deployment of MD/HD fuel cell vehicles will require the development of novel hydrogen fueling technologies that can enable fills that are over five times faster than those of light-duty hydrogen fueling stations. While a fueling protocol for MD/HD fuel cell vehicles has not yet been established, the DOE’s target for hydrogen fueling of 700 bar onboard storage tanks include a fill rate of 10 kg/min with a hydrogen gas temperature of -40 °C [1]. Hydrogen chillers that can achieve -40 °C fills are commercially available, but do not meet the flow rate and cooling capacity requirements of MD/HD vehicles. Cooling capacities of up to 100 kW will be necessary to facilitate 10 kg/min refueling at -40 °C.[2]


Proposed concepts must adhere to the flow rate and temperature standards of 10 kg/min (maximum) and -33 °C at the point of dispensing within 30 seconds; however, viable alternatives to temperature standards will be considered. Proposed concepts can range in scope from component to system level. Examples include, but are not limited to, chillers that enable on-demand supply of cold hydrogen, short-term intermediate cold storage, and systems that circumvent hydrogen precooling. Proposed concepts should be applicable for use of either gaseous or liquid on-site bulk storage of hydrogen, however on-site hydrogen liquefaction concepts will not be considered for this subtopic.


Phase I of the project is expected to focus on an in-depth analysis of the system or component(s) proposed, refueling protocol efficiency and overall costs. Testing protocols, including safety, should also be established as a part of Phase I. Phase II will focus on prototype development and testing at the laboratory scale.


Questions – Contact: Neha Rustagi,


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