Hydrogen- Powered Fuel Cell Range Extender Vehicle- Long Driving Range with Zero- Emissions

Hydrogen as carbon-free energy carrier, produced from renewable sources like wind, solar or hydro power, is a promising option to overcome the impacts of the anthropogenic climate change. Recently, great advances regarding the early market introduction of FCVs have been achieved. As the availability of hydrogen refueling stations is highly limited, a modular, scalable and highly efficient hydrogen supply infrastructure concept is presented in this paper. The focus lies on cost-effectiveness and flexibility for the utilization in different applications and for growing markets. Based on the analysis of different use cases, the requirements for the newly developed concept are elaborated. The modular system design, utilizing a standardized high pressure PEM electrolysis module, allows a scalable hydrogen production of up to several hundred kilograms per day. The high pressure electrolyzer produces hydrogen at 35 MPa without mechanical compression and offers the following benefits: highest system efficiencies, dynamic operational behavior, good partial load behavior, low maintenance efforts and highest hydrogen qualities. Refueling processes at both standardized filling pressures, 35 MPa and 70 MPa, can be realized. A major advantage of the modular concept is the capability of a subsequent extension in order to adapt the infrastructure to growing demands. The developed concept represents an important factor for the market penetration of hydrogen technologies as the utilization of a standardized electrolysis module will lead to significant cost reductions as of increasing production figures. Three implementation concepts with different hydrogen capacities are presented: a small-sized infrastructure for home refueling with 1.5 kg/d, a medium-sized infrastructure for industrial utilization with up to 50 kg/d and a large-sized infrastructure with more than 100 kg/d.