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Review

Perspective on hydrogen energy carrier and its


automotive applications

Giovanni Cipriani a, Vincenzo Di Dio a, Fabio Genduso a,*, Diego La Cascia b,


Rosario Liga a, Rosario Miceli a, Giuseppe Ricco Galluzzo a
a
DEIM, Department of Energy Information Technology and Mathematical Modeling, University of Palermo,
Viale delle Scienze, 90128, Block 9, Palermo 90128, Italy
b
DICGIM, Department of Chemistry, Industrial Management, Informatics, and Mechanical Engineering,
University of Palermo, Italy

article info abstract

Article history: The paper outlines the concept of energy carrier with a particular reference to hydrogen, in
Received 8 January 2014 view of a more disseminated employment in the field of automotive applications. In
Received in revised form particular hydrogen production is analyzed considering the actual state of the art and
19 March 2014 recent technologies applied in production from the primary sources (fossil fuels, renewable
Accepted 23 March 2014 energies, and water electrolysis). Then the problem of hydrogen storage is considered both
Available online xxx from technical and economical point of views. In particular, differences between physical
and chemical storage are here considered with a particular glance to the most innovative
Keywords: technologies including carbon nanostructures. A review on the main problems in storage
Energy carrier and transportation is then shown with a particular attention given to infrastructures costs
Hydrogen that perhaps will address particular choices for the technologies of the next future.
Storage Automotive applications are called out, accounting the main current technologies and
Transportation notes on fueling station for hydrogen fed vehicle. The discussion of hydrogen safety in
automotive put in evidence the needs for sophisticated sensors, but a comparison with the
safety of gasoline and fire risks, evidences that some common incertitudes on hydrogen
usage should be overcome. Some other safety issues are introduced in the section of
hydrogen transportation. An overview of costs related hydrogen production, storage and
transportation is finally given. This aspect is of a capital importance for the future
dissemination of the hydrogen energy carrier.
Copyright ª 2014, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights
reserved.

Introduction and quality of life are some of the main causes of the restless
growth in energy demand and in the concurrent increase in
The growth of the world population and the natural aspiration pollution (especially for CO2). Meeting this energy demand is
of new out-coming countries to achieve high economic levels most important technology challenge of the 21-st century

* Corresponding author.
E-mail addresses: fabio.genduso@unipa.it, genduso@dieet.unipa.it (F. Genduso).
http://dx.doi.org/10.1016/j.ijhydene.2014.03.174
0360-3199/Copyright ª 2014, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.

Please cite this article in press as: Cipriani G, et al., Perspective on hydrogen energy carrier and its automotive applications,
International Journal of Hydrogen Energy (2014), http://dx.doi.org/10.1016/j.ijhydene.2014.03.174
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[1e5], keeping however low levels of pollution and, thereby,


reducing the medium term risk of climate change. Such a Hydrogen production
scenario should ideally be based on an energy carrier with
negligible environmental impact (either locally and globally) Since it is impossible to find hydrogen as available molecules
[6,7]. Energy should be produced more by primary inter- in nature, it has to be produced from other materials that
changeable and available energy sources and with preferably contain it. In particular, hydrogen can be produced from fossil
distributed locations across a network. fuels and hydrocarbons, or even from renewable sources. In
Hydrogen is an energy carrier able to fully satisfy such the following, the most common processes for hydrogen
requisites because: production are recalled [20e25].

 its air combustion produces energy and pure water only as Production from fossil fuels and hydrocarbons
the unique reaction product;
 it can be produced from fossil fuels and, hopefully, from Among the methods of hydrogen production from fossil fuels
renewable sources; and hydrocarbons, the most suitable are [26e34]:
 its energy can be distributed quite easily, in accordance
with the end user requests and with the development of  catalytic steam reforming (steam reforming of natural gas
new technologies for transportation and storage; or oil);
 it may be used in different applications such as centralized  steam reforming of methanol;
or distributed energy production, specific heat production  coal gasification;
with an extremely reduced, impact.  partial oxidation of hydrocarbons;
 alternative technologies (process or Kvaerner Termoc-
In view of its special and environmental quality, hydrogen racking).
as an energy carrier requires the development of optimum
technologies for production, transport, storage and usage In the catalytic steam reforming, used only for light
[8e15]. Once the technological issues are satisfied, the gradual hydrocarbons (methane and naphtha), it is possible to
market introduction of hydrogen-powered vehicles will raise identify three stages of hydrocarbon treatment: generation
along with the problem of organization and support of infra- of synthesis gas, shift reaction reforming, gas purific
structure, guaranteeing the production and distribution ation [22].
within the countries of this interesting fuel. As can be seen from the simplified block diagram of this
Technology, logistics and economic issues are, in this process (Fig. 1), after an initial desulfurization phase, the gas
case, strongly connected each other. The introduction of passes through a reformer, constituted by a system of steel
hydrogen-powered vehicles is actually hampered by inade- pipes containing a nickel based catalyst, where the steam
quate distribution networks, whose growth can not be enter obtaining a gas with a variable content of CO and CO2
achieved without a critical mass market to justify the between 10% and 15%. The shift reaction reforming allows to
necessary investment. The problem of planning logistics decrease the CO and CO2 content up to 0.2e0.4% of volume.
and networks is further complicated by the large number of The final stage allows the purification of the gas from the re-
existing technological alternatives. These strongly influence sidual CO and CO2.
costs, and the interdependence between the logistics In the methanol steam reforming a molecule of methanol
infrastructure and the technological choices made by vehi- (CH3OH) is separated into hydrogen and carbon monoxide:
cles manufacturers [16e19]. the process consists in an initial decomposition of
The paper is clearly a summary of many possible issues, methanol, followed by a shift reaction and subsequent
some of which would have deserved a deeper analysis. It removal of CO2 [8].
want to introduce the reader into the consideration of Gasification is an high temperature endothermic reaction
very promising technological field. Clearly, for the sake of of pulverized coal, pure oxygen and water steam, to produce a
clarity and synthesis, every aspect can not be deeply gas mainly consisting of hydrogen and carbon monoxide. In
analyzed and discussed, but a large bibliography extent is this process, finely chopped mixed coal and water forms a
finally given. mash pumped into the reactor, where oxidation reaction with

Fig. 1 e Simplified scheme of catalytic reforming.

Please cite this article in press as: Cipriani G, et al., Perspective on hydrogen energy carrier and its automotive applications,
International Journal of Hydrogen Energy (2014), http://dx.doi.org/10.1016/j.ijhydene.2014.03.174
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y x x x ( 2 0 1 4 ) 1 e1 3 3

Fig. 2 e PDX process base reformer realized by Nuvera Fuel Cells.

pure oxygen finally happens. From the obtained gas, powders  photo-electrochemical conversion;
and traces of H2S are then eliminated.  water electrolysis.
Hydrogen can also be derived from residues of crude oil
and hydrocarbons processing, by a reaction with water steam The biomass is the biodegradable fraction of products,
and oxygen. The partial oxidation of liquid hydrocarbons waste and residues from agriculture (including vegetable and
(PDX) is a process used to produce hydrogen in all those cases animal organic fertilizers), forestry and related industries, as
in which natural gas is not economically available [35]. well as the biodegradable fraction of industrial and city
Structurally, the reactor conducting the partial oxidation is garbage [39]. Thermochemical processes currently used for
very similar to the reformer used in the steam reforming the production of hydrogen from biomass gasification and
process, but it does not contain any catalyst. Moreover, in this pyrolysis are fast [32,33,40,41].
case, the heat steam production is realized in a vertical reactor The gasification process starts from converting the
by combustion of a part of the incoming fuel with a controlled biomass into a synthesis gas by partial reaction with oxygen
air amount, without the need for additional contribution of and with the use of heat. The synthesis gas is composed pri-
external fuel (see Fig. 2). The main disadvantages, however, marily of hydrogen CO, methane CO2, water steam and other
are related to the need of pure oxygen and the significantly hydrocarbons, in dependence on the reactor type. This gas is
lower conversion efficiency, compared to that of the steam then chilled, purified from sulfur compounds, and submitted
reforming.
The previously described hydrogen production methods
determine a not negligible pollution of CO2. The Kvaerner and
Termocracking processes improve, instead hydrogen pro-
duction with lower pollution. These processes, however, have
higher costs and lower efficiencies. In particular, the Norwe-
gian Kvaerner Engineering has developed an innovative pro-
cess in which hydrocarbons are separated into atoms of
carbon and hydrogen (CH4 / C þ 2H2), using a plasma at of
1600  C. Hydrogen is then obtained without emission of car-
bon dioxide. In the Termocracking technology, however, the
reaction is the same of the previous process, but it is different
because the decomposition of the hydrocarbon molecule oc-
curs free of air and at high temperature water steam
atmosphere.

Production from renewable sources

The production of hydrogen from renewable sources is now


more and more interesting from the technological point of
view because of the development of some methodologies,
among which we mention the following [21,23,24,36e38]: Fig. 3 e A plot of hydrogen uptake (WH2 at 77 K, 1 MPa)
versus BET surface areas SBET of nanoporous carbons and
 thermochemical processes from biomass; composites, together with other high-performance
 thermochemical decomposition of water; materials (AC and MOF).

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to reforming and shift reforming reactions, which two the way of hydrogen employments as for as all other tradi-
different processes to produce hydrogen and methanol. tional fuels.
Fast pyrolysis is a thermal degradation process of the The storage problem is the main one in automotive appli-
biomass that occurs in absence of oxidizing agents and cation, where weights and volumes should be kept as lower as
producing: possible. At the present stage the available hydrogen storage
technologies are classified as follows [8,10,12,51e86]:
 a gaseous part, characterized by a medium-low calorific
value and containing CO, CO2, hydrocarbons, water steam  physical storage (compressed hydrogen also as liquid) in
and hydrogen; glass micro-balls;
 a liquid fraction made up of low molecular weight organic  chemical storage in metal hydrides;
compounds such as aldehydes, alcohols and acids;  storage by means of carbon nanostructures.
 a solid fraction, consisting of a higher molecular weight
residues.
Physical storage
The production of liquid fraction (bio-oil, with a calorific
value higher than the initial biomass) with fast pyrolysis is The easiest and cheapest way to accumulate and store
maximum, allowing to resolve the difficulties related to the hydrogen is to compress it in tanks, with technologies very
biomass transport. The actual conversion into hydrogen can similar to those used in the compression of natural gas. The
take place via a catalytic reforming of bio-oil product. storage tanks are normally made of aluminum, glass fiber or
The plants that exploit the decomposition process is based carbon fiber and polymeric materials. These tanks are very
on thermochemical water cycles in which hydrogen and ox- often used in automotive application (see also Section 5)
ygen are produced by the decomposition of water. This is done Hydrogen is stored at a pressure of about 25 MPa. However, for
by means of a series of chemical reactions in which chemical vehicle applications, new composite materials with a signifi-
intermediates (typically sulfuric acid) are formed and are cant reduction of weights and encumbrance are being
recycled inside the process. considered. A significant progress has been made with the
To operate at the necessary 1000e1300 K solar concentra- introduction of reinforced carbon and glass fibers tanks with a
tors, distributed into different areas, are used. Solar concen- weight 3e4 times lower than that of the common tanks and
trators provide heat at the temperature levels suitable for the pressures up to 35 MPa (potentially even 70 MPa).
different reactions. The conversion process consists in photo- The usual safety features are very high thanks to the
electrochemical split of the water molecule into oxygen and robustness of the tanks, to the introduction of nonexplosive
hydrogen using sunlight. The operation principle is similar to fuses in case of fire and to the presence of interrupting circuit
that of photovoltaic cells [42,43], where electronehole pairs in the case of impacts (see also Section 5.4) [58].
are created at the semiconductors underwater electrodes, The Daimler-Chrysler used compressed hydrogen on the
with a resulting current circulation and the resulting first two fuel cell car prototype (Fuel Cell car - FCV), NECAR
hydrogen generation. NECAR H and I, and the recent NECAR 4a. The P2000 FCV Ford
The main difficulties of this technology lie in the avail- and the Fiat 600 Electra are other examples of cars using
ability of semiconductors being good sunlight absorbers and hydrogen tanks. The applications of this storage technology is
stable in water at the same time. To this aim, cells with in- practically the same on the most part of fuel cells buses pro-
tegrated electrodes and protective films, achieving conversion totype. Hydrogen can be also stored in liquid form (at 253  C),
efficiencies up to 15% are under investigations.
Electrolysis is the combination of electrochemical phe-
Table 1 e Energy density of some energy carriers.
nomena determined by the circulation of an electric current
through an electrolyte. In particular, water electrolysis de- Energy Way of Energy density Energy
termines the decomposition of water into hydrogen and ox- carrier storage by weight density by
[kWh/kg] volume
ygen (the latter in a double volume compared to the first). Pure
[kWh/l]
water, although little dissociated, contains ions Hþ and OH
Hydrogen Gas (20 MPa) 33.3 0.53
which, because of the electric field action, migrate toward the
Gas (24.8 MPa) 33.3 0.64
cathode and the anode to form hydrogen and oxygen [44e48]. Gas (30 MPa) 33.3 0.75
However, given the low electrical conductivity of pure water, Liquid 33.3 2.36
electrolysis should be carried out in the presence of suitable (253  C)
dissolved electrolytes, in order to increase the conductivity of Metal hydrides 0.58 3.18
the solution. The compounds to be added in water can be Natural gas Gas (20 MPa) 13.9 2.58
Gas (24.8 MPa) 13.9 3.01
acids, bases or salts.
Gas (30 MPa) 13.9 3.38
Liquid 13.9 5.8
(162  C)
Hydrogen storage LPG Liquid 12.9 7.5
(Propane)
In automotive traction application hydrogen storage is a Methanol Liquid 5.6 4.42
capital issue [49,50]. Industry and researchers are using all Gasoline Liquid 12.7 8.76
Diesel Liquid 11.6 9.7
their resources to investigate within the safety limits, to find

Please cite this article in press as: Cipriani G, et al., Perspective on hydrogen energy carrier and its automotive applications,
International Journal of Hydrogen Energy (2014), http://dx.doi.org/10.1016/j.ijhydene.2014.03.174
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raising its energy density, as can be seen from Table 1, membrane fuel cells for vehicular applications. The main
compared to that characteristic of other compressed gas. advantages of such a storage technology are low pressures,
However, the very low temperature implies considerable large energy densities greater than those of liquid hydrogen
problems, especially with regard to losses. In fact, being the (see Table 1).
hydrogen at the boiling temperature, even a minimum heat A weakness of this technology is the weight of these stor-
exchange produces evaporation and, therefore, a dangerous age systems: in fact, for the same weight of different tech-
emission which affects also the autonomy of the vehicle. The nologies, the vehicle exhibits an autonomy three times lower
phenomenon is particularly evident in small size cylindrical than that obtainable with liquid hydrogen or compressed
tanks for vehicles, where the evaporation rate is 2e3% per day. hydrogen advanced tanks. In terms of safety, the risk of un-
This phenomenon is less evident in spherical tanks of thou- wanted losses, even in case of a car impact, is really minimal
sands of m3 (because the spherical form allows to minimize for this storage.
the heat exchange surface, with equal stored volume). In this The technology of the hydrides is being studied in the
case losses are reduced to percentage fractions per day. These United States, Europe and Japan, where Toyota has developed
storage systems are made of composite material with double special titanium alloys, as part of its program of development
wall tanks and a vacuum inter-space (reservoirs of type of Fuel Cell Vehicle [44e48].
DEWAR) in order to minimize the exchanges by conduction
and convection. Storage through carbon nanostructures
This storage technique has a further disadvantage: it re-
quires a high amount of energy and is therefore a source of Since the early 90’s some particular forms of carbon graphite-
considerable environmental impact. Among the FCV recently like aggregations have been investigated, because they are
produced with liquid hydrogen, the NECAR 4 of Daimler- able to accumulate hydrogen. Although hydrides generally
Chrysler and Opel HydroGen 1 are to be reminded. They also exhibit a high storage capacity of over 5 wt%, there are several
use liquid hydrogen buses built by Ansaldo (3600 L tanks by drawbacks such as the necessity of heating for hydrogen
Messer Griesheim, located on the rooftop of the bus) and MAN release, slow re-hydrogenation rate, and poor cyclability.
(3200 L Linde tanks, placed on the floor of the vehicle). Another Nanoporous materials, especially carbons, are free from most
disadvantage of liquid hydrogen, finally, is the greater of these problems [55,63,65,70,71,81,82,90], but the only
complexity of the whole system, above all for distribution and drawback is a lack of sufficient storage capacity, especially at
supplying, and the higher costs associated with. room temperature (ca 1 wt%). Thus, increasing physisorption-
Hydrogen storage in glass micro-spheres represents a based storage capability is the most important task for
technology, studied along time, which exploits the hydrogen nanoporous materials. Physisorption is based on the Van der
permeability of the glass at high temperatures. Waals forces between a solid surface and a hydrogen mole-
The micro-spheres (with diameters of 25 up to 500 mm), cule. The interaction is very weak and the heat of adsorption is
heated up to 200e400  C, are filled with tens of MPa pressur- as low as 6/8 kJ/mol in nanoporous carbons [70,82]. On the
ized hydrogen. The pressure limit is given by the micro- basis of physisorption, large surface area [61,91], large
spheres resistance, usually up to 340 MPa. To get hydrogen a micropore volume [55,65], and a suitable pore size [55,65,66]
further heating of the glass causes the breakage of the micro- are highly desirable for a large amount of adsorption. There
spheres: in the latter case, obviously, the storage system can are two target temperature ranges for physisorption-based
be used only once, but glass can be however recycled. This hydrogen storage: liquid nitrogen temperature (77 K) and
system is considered as a possible technology suitable for the room temperature. The values of hydrogen uptake
construction of a hydrogen tanks for motor vehicles, espe- ðWH2 at 77 K; 1 MPaÞ are plotted against their BET surface
cially with regards to the intrinsic safety concerning any fuel areas in Fig. 3, which reveals that WH2 is basically proportional
leak. to SBET, and that the data of the nanocarbons having higher
WH2 =SBET values (ZTC, N-ZTC, and other) can be plotted along
Chemical storage by metal hydrides a line of 10 mmol/m2, while those of OMC, OMC/M, AC, and
MOF are along a line of 7 mmol/m2.
Some metal alloys can store hydrogen atoms within their Large surface area, a high fraction of micropores and a
crystalline reticulum to form a hydride: the extremely positive stronger surface affinity are important for the hydrogen
peculiarity of a metal hydrides accumulation is to maintain storage based on physisorption at cryogenic temperature and
the gas at environmental temperature and pressure, since at room temperature [54,61,63,65,67,68]. Porous carbons have
hydrogen penetrates into the crystal reticulum occupying the the advantage of a stronger affinity compared to MOFs.
interstitial sites [87e89]. The hydrogenation process is Particularly, ZTCs exhibit the best performances among all
exothermic (i.e. the device must be cooled while charging) and other microporous materials. Although the highest amount of
takes place at pressures of 3e6 MPa. The dehydrogenation storage 5.7 wt% at 77 K under 1 MPa, has been achieved by
requires, instead, heat (at a temperatures which depends on CB850h having an SBET of 3150 m2/g, it is actually possible to
the used alloy) and an initial at high pressure which is grad- prepare ZTC with a higher SBET of up to 4100 m2/g. If such a
ually decreased. Hydrides are classified according to their ZTC retains the specific adsorption amount (10 mmol/m2), the
dehydrogenation temperature. hydrogen uptake is estimated to be 7.6 wt%. Of course, under
The actual research is addressing towards the identifica- higher pressure, its storage amount is further increased; for
tion of hydrides characterized by low temperatures (below example, CB850h exhibits 6.9 wt% at 2 MPa [82], i.e., 1.2 times
100  C), so that they can be coupled with a polymeric larger than at 1 MPa.

Please cite this article in press as: Cipriani G, et al., Perspective on hydrogen energy carrier and its automotive applications,
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In addition, the surface affinity of carbon materials to The second solution is obviously more advantageous from the
hydrogen could be enhanced by lithium doping [59,79], and point of view of the energy transport, but involves higher costs
thereby additional higher capacity might be achieved. The because of the required insulation and the refrigeration sys-
experimental data on hydrogen storage by nanocarbons on tems. As well as for transportation by pipeline, also in this
models at room temperature are shown in the diagram in Fig. 4. case, the costs are a function of the distance and the transport
While OMCs show very poor hydrogen capacity (<0.1 wt) of hydrogen in liquid form is not the most convenient solu-
[53,54], much higher capacities have been reported for ZTCs by tion, both for investments and for units of transported energy.
Wang et al. [67,78] and Nishihara et al. By increasing hydrogen The transport by rail is intermediate between pipelines and
pressure up to 34 MPa, the capacity reached 2.2 wt% [70], and trucks transportation investments [9,17].
this is one of the highest storage values among nanoporous
carbons reported. Nevertheless, it is still far from the target for
practical use (>6 wt%). The highly microporous templated Hydrogen in automotive
nanocarbons, such as ZTCs, are superior to OMCs or other
templated nanocarbons with larger pores. Surprisingly, the The actual society development is strongly conditioned by
high-performance AC shows a storage capacity comparable to transportation and particularly by automotive. Conversely,
those of ZTCs, indicating great potential for conventional ACs, the adoption of new solutions can not introduce damages or
which enjoy both low production cost and ease of mass pro- risks for the actual modern world. By analyzing the pollution
duction. In this case it is expected that the lithium doping in- of NOx and COx chemical compounds due to road trans-
creases the physisorption amount up to 2O4 times [59,73]. portation, it is evident that its reduction become mandatory
Accordingly, the lithium doping into highly microporous car- and some specific actions must be planned and managed [99].
bons such as ZTC may be one of the interesting approaches to To gain more effective actions in reducing pollution,
achieve much higher storage capacity than 2.2 wt%. transportation requisites must be globally accounted in the
development of both new vehicular technologies and new
fuels exploitation [100]. Beyond the modern engine enhance-
Transport and distribution of hydrogen ments, different solutions may be based on electric vehicles
technologies with high efficiency motors for the most part of their torque -
speed range and with the further capability of energy recovery
In order to hold hydrogen as a common fuel, there is the need during breaking.
of an efficient transportation and distribution network which
must meet the usual requirements to which users are accus- Fuel cells vehicles
tomed, such as security, quick and easy supply stations all
across the country. Hydrogen can be delivered via pipeline or Nowadays, among the various proposed solutions, fuel cell
transported by means of land and/or naval vehicles [92,93]. vehicles appear a viable solution within the medium - long
At present the existing hydrogen distribution networks, time range. Fuel cell cars started as an evolution of lead acid
both in Europe and the United States, are pipelines within any battery fed cars whose main problems were the large weight
given industrial district [94]. The most obvious problem suf- and extension of the battery pack and the long lasting time for
fered by pipeline [41,95] is the embrittlement of materials in their recharge.
contact with the hydrogen that determines an increase of Hydrogen fuel cells drastically reduce both these problems
losses along the pipe itself. The embrittlement can be reduced [99]. In general the architecture of such vehicles is essentially
by adopting metals pre-processing to minimize residual hybrid, because both battery packs and fuel cell usage are
stresses in the material [11,16,36,93,96,97]. there proposed. This is in order to guarantee a better capa-
The use of pipelines for the distribution of liquid hydrogen bility to cover all the requirements of normal operation,
would greatly increase the transport capacity, in front of transients (accelerations, braking, non regular mileages and
higher investment costs. In fact, pumping systems, cooling so on) and a longer life for the stack. A possible alternative to
and heat-insulated pipes become mandatory [98]. In this case, battery packages is their substitution with storing energy ca-
safety problems are multiplied, because, in case of pipe leaks, pacitors. Thanks to capacitors capability of fast charges and
there would be a deep cooling of all the materials in contact discharges, a better and prompt response to sudden load
with hydrogen (with higher hazard for the personnel). variations can be guaranteed. Unfortunately the presence of
Furthermore, if the thermal insulation is not perfect, the all capacitors implies a greater complexity of the control system.
around atmosphere with more than 50% oxygen content be- Nowadays three main vehicular architectures can be
comes extremely flammable. The problem of adapting the considered really suitable. They are briefly described below.
existing natural gas pipeline for use with hydrogen is
currently under study, but there are no general conclusion on 1. Load leveler. In this architecture fuel cell delivered power is
the best way to face the problem [41,95]. slightly higher than that given by the battery packs. This
If the hydrogen demand does not justify the massive last ones are mainly used with high starting torques. Bat-
installation investment of dedicated pipeline, hydrogen can tery packages are then recharged in more favorable
be easily transported by road via trucks, using different stor- running conditions. This configuration is well suited for a
age technologies analyzed above. In particular, this transport typical urban cycle [101].
is realized with tanks containing more cylinders of com- 2. Range extender. In this architecture fuel cell delivered power
pressed hydrogen or liquid hydrogen at a pressure of 20 MPa. is lower (typically less than the 25%) than that given by the

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battery packs. This configuration allows a greater auton- Hydrogen fueling stations
omy and result well suited for high mileages with a
reduced space amount for the battery pack itself. It is also By using consolidated technologies, different option are
the best configuration for large vehicles destined to the available to realize hydrogen fueling stations:
transportation of both peoples and goods. A high power
stack would imply a more expensive system and should be 1. Local production via electrolysis and different storage
designed based on the peak power, even if this last is not forms (hydrides, gaseous, etc.);
always requested. The larger space available allows the 2. local gaseous storage and transport with trucks as in the
presence of more than one battery pack. The stack can case of fossil fuels;
work continuously with a good efficiency and a larger 3. liquid local storage and transportation with tracks;
lifetime. 4. local production from gaseous methane, purification and
3. Full power. In this architecture the whole power is delivered storage in different forms (hydrides, gaseous hydrogen,
by a fuel cell stack. An extra urban cycle with long mileages etc.);
and rare transients tend to discharge the battery pack 5. pipe distribution and local compressing stations, as in the
quickly. It is thus convenient that power is delivered from case of natural gas.
the fuel cell stack. This configuration can however provide
a certain level of hybridization. The control system man- Except for the last item, that needs a still non existing
ages the electric drive motoring extracting its energy from hydrogen distribution network, all the other technologies are
the stack or from the small battery pack, according to the well known and the only issues are in normative and com-
vehicle or to the route characteristics. ponents standardization. There is in fact no commonly
accepted standard for hydrogen fueling stations. On the other
hand, hydrogen uncommon usage as a fuel implies that
Internal combustion engines vehicles applied conditions are often severe and restrictive. Yet, for
components standardization (e.g. for tanks valves and con-
The modern technologies allow the direct usage of hydrogen nectors) there are no particular trends and any each manu-
inside an internal combustion engine with some modifica- facturer uses to refer to its own technical specifications
tion made on the usual gasoline engines to adapt them to coherently with some other international standards referred
hydrogen. In particular the principal modification regards to particular environment with flammable gases.
the electronics unit control to properly manage the pressure
in the injection and in hydrogen combustion. It is also Hydrogen safety in automotive
important to provide sensors to avoid self combustion in-
side the chamber, that is positive in traditional engine, but The main incertitude on hydrogen fuel diffusion are related to
completely undesired in hydrogen engines. The same en- safety issues, but, going beyond one’s personal perception, a
gine fed by hydrogen lose a certain amount of power with careful analysis reveals that hydrogen results less flammable
respect to the gasoline usage because of the smaller energy than gasoline. In fact, hydrogen self ignition temperature is
of the compound inside the cylinders. Furthermore, the 550  C whereas the gasoline one is 230e500  C, according to
lower volumetric density of the air/hydrogen compound different types. First of all, it must be emphasized that
does not facilitate an optimal fill in of the combustion hydrogen safety requirements in automotive are quite
chamber. different from those considered in transportation as for
The fuel cell vehicle efficiency is clearly higher than that pipelines as for transportation through trucks because of the
of the internal combustion engine vehicles. Yet the effi- different concentrations and amounts of the managed
ciency of a low temperature thermal cycle is not satisfac- gaseous mass.
tory and became suitable only at higher temperature Hydrogen is very volatile and, possibly, it is very quickly
that are difficult to reach for structural issues and high dispersed in the environment. It is also practically impossible
costs. Fuel cell vehicles have no pollution while hydrogen to make hydrogen explode except for very reduced spaces.
internal combustion engines pollutes dangerous nitrogen To find potentially dangerous hydrogen concentrations in
mixtures. The only advantage of hydrogen internal com- the air, different sensors are used to manage proper safety
bustion vehicles is their immediate availability thanks to control systems. Different, but common, commercial sensors
well known engine technologies eliminating CO and CO2 operate according to different hydrogen detection principles.
emissions. Among them catalytic beads, electrochemical and Metal-
Apart from some general aspects, the design of an internal Oxide-Semiconductor-sensors are the most exploited in the
combustion engine must be clearly and carefully devoted to current market.
the main characteristics and properties of hydrogen. The
paper [99] gives a large overview on hydrogen usage as fuel in  The catalytic bead sensor typically contains two platinum
internal combustion engines and carefully accounts the wires coated with beads, a sensing bead and a reference
aspect of abnormal combustion avoidance, in order to gain bead. The reference bead compensates environmental ef-
efficiency and to increase output power. For this reason in [99] fects, humidity and temperature. The two beads, a fixed
all the main engine components are analyzed to underline the and a variable resistor, are mounted on a Wheatstone
main criteria to follow in the proper design of an efficient bridge. When target gas comes, a catalytic combustion
hydrogen fed engine. takes place on sensing bead and generates combustion

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heat causing an increase of sensing bead temperature. The costs grow significantly in the case of production from
Thus, platinum wire resistance changes causing the the coal gasification: this is due, mainly, to the greater
Wheatstone bridge unbalance and provides an output complexity of the technology and the need for a thorough
signal variable with the target gas concentration. cleaning and gas purification. However, in countries such as
 The electrochemical sensor consist of three electrodes South Africa or China, the lower cost of coal with respect to
separated by an electrolytic solution. When target gas methane, can make this process very convenient. Using the
penetrates the gas diffusion barrier it reaches the surface partial oxidation technology, the penalties under the technical
of the first electrode. Thus, an electrochemical reaction and energy are even stronger: there are, in fact, much greater
takes place releasing electrons which contribute to the weight, volume and cost. The presence of oxygen in the re-
generation of an output signal. Thermal Conductivity actors lead to problems similar to those of aboard compressed
sensors are also mounted on a Wheatstone bridge with two hydrogen storage. For air picking up the resulting dilution of
cells, a measurement and a reference cell. the nitrogen stream (in addition to CO2) would reduce further
 Metal-Oxide-Semiconductor-Sensors (MOSS) consist of the power of the fuel cell. The cost increase compared to a
three stacked layers, a substrate, usually Silicon, followed conventional vehicle is, in this case, approximately USD
by a thin oxide layer and finally a sensitive metal layer. The 3400e6300.
operating principle is based on measuring the capacitance The centralized production requires significant storage and
variation caused by the changes in MOS device character- distribution costs for end users [10,25,75,79,104,120,121]. Even
istics due to the variation on the sensing layer in presence assuming a centralized production by catalytic steam
of the target gas [102]. reforming plants, consider that a hydrogen transport for
55 km costs 8 times more than carrying an energy-equivalent
When burning, hydrogen is very quickly consumed, always amount of gasoline for 3000 km.
with direct upwards flames, and its thermal radiation wave- Due to possible developments of compact reformer, the on-
length is very low, thus it is easily absorbed by the atmo- site production will become, therefore, probably better than
sphere. It has been calculated, by experimental data, that the that centralized distribution through pipeline, at least until a
fire of a gasoline vehicle lasts for 20e30 min, while for a sufficiently high demand increase.
hydrogen vehicle it does not last more than 1e2 min. The low Adopting smaller plants size but a better distribution
thermal radiation, also implies that there is little contingency throughout the territory, the production would be advanta-
(except for a direct exposure to the flames) for neighbors geous for catalytic steam reforming of natural gas, or by steam
materials to be burned, thus reducing the duration of the fire reforming of methanol, or through electrolysis of water,
and the danger of toxic pollution. providing the necessary electricity through the existing dis-
Hydrogen is not toxic, nor corrosive. Conversely, all fossil tribution network or producing it locally from renewable
fuels are asphyxiating and toxic to the human beings. Any sources.
hydrogen leaks from tanks do not involve poisoning of soil The electrolysis process, that achieves high flexibility and
and groundwater. no environmental impact if electricity generation, is based on
renewable sources such as wind and solar power, but these
sources are usually characterized by discontinuity of power
Costs of hydrogen production, storage and delivery. Indeed, during the periods of superabundant elec-
distribution trical power production, the produced hydrogen can be stored.
The cost of production by electrolysis is the highest among all
The development of hydrogen as an energy carrier requires
the preparation of a wide range of integrated infrastructure to
make the entire system reliable and cost-effective (produc-
tion, transportation, distribution, storage, end use) [103]. All
the infrastructure elements are strongly dependent each
other, so that the choice of methodology and technology for
the realization of the system may condition all the others,
both technically and economically [58,83,95,101,103e117] (see
Fig. 4).
The production can take place, according to the processes
described in Section 2 and the costs of which are briefly shown
in Fig. 5 [8,11] in:

 large size centralized systems;


 plants of smaller size throughout the country (on-site);
 installations in vehicles.

In the first case the production would take place from Fig. 4 e A plot of hydrogen uptake WH2 at room
natural gas by catalytic steam reforming; this is the most temperature, 10 MPa, versus BET surface areas SBET of
widely used more convenient and commercially mature nanoporous carbons and composites, together with other
method, for the hydrogen large scale production [118,119]. high-performance materials (AC and MOF).

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the technologies considered, but it is also the only process that that of gasoline, while the cost of transport per unit of latent
allows the production from water using electricity. The eco- energy is doubled [11,12].
nomic investment is at least twice that required for the In the case gasoline fed vehicles, all costs related to the
reforming. In the case of on-site production smaller plants are distribution infrastructure are erroneously deleted. In fact, to
more expensive, but distribution costs results highly reduced. avoid poisoning of the catalysts in the reformer, a tight control
As for the centralized system, even in the hydrogen of the sulfur content becomes necessary: therefore it is
distributed production, investment and management costs of essential a radical reorganization of the refineries.
the storage systems are very relevant. In particular, storage of Moreover, the producers are very often reluctant to invest
compressed hydrogen is characterized by high operating costs in significant plant modifications, standing the current
due to the energy expenditure required to perform its narrowness of the market. The cost of gasoline, however,
compression (7e18 kW/GJ) and to the low volumetric energy should not change too much, as the increased costs of the
density of the tanks (1.3e3.4 MJ/l with 32.4 MJ/l of gasoline) desulfurization would be offset by the lower octane required.
[98]. The desulfurization may also be carried on board the vehicle:
Also for liquid hydrogen system operating costs are sig- however, the optimal solution from the economic point of
nificant, being essentially due to the consumption of elec- view [10] seems to be represented by the trade off between
tricity for compression and liquefaction (82e160 kW/GJ) and reducing the sulfur content in the refineries and perfecting its
can cover the 30% up to 80% of the entire storage cost. removal aboard by means of a cheap treatment systems (with
Among the disadvantages of metal hydrides technology an estimated cost of USD 50 for a filter whose time-line
[88] it is important to emphasize its high cost due to problems approach that of the vehicle).
of metal alloys availability, using rare earth [9]. Given the lack of a distribution network, the production of
In the third case, the hydrogen production through small- hydrogen in vehicles will be the pursued solution in the short
scale reforming plants would be installed in vehicles, from term since it allows, in spite of the difficulties encountered by
traditional fuels, such as gasoline, diesel or methanol and the board reforming, a significant reduction of barriers in the
natural gas, which would be distributed using existing infra- market entry.
structure [19,29]. In this way the transport costs would be One of the actual challenges is the reformer scale-down,
eliminated, but the car purchaser would be placed against the namely the creation of a small size reformer (a few units or
costs of production and storage on board. Among the tradi- tens of Nm3/h) with cost per liter of hydrogen comparable to
tional fuels methanol plays an important role since, like the that of plants large size. The research in the field of fuel cells is
others, it is easily transportable, but more easily convertible leading to the development of compact, standardized and
into hydrogen. high technology reformers, operating at pressures and tem-
In fuel fell vehicles fed by methanol, the presence on board peratures lower than those of the conventional reformer, with
of the reformer and the gas purification from CO determines advantageous investment costs compared to conventional
an increase of cost of about USD 2300e3400, compared to a installations steam methane reforming. Furthermore, when
conventional vehicle, and approximately of USD 1800e2200, such plants are produced, the specific costs of hydrogen pro-
compared to a direct hydrogen-powered fuel cell vehicles duction is unaffected by the size of the plant.
[72,122,123]. Since the methanol is also toxic, corrosive and Limiting the attention to production costs with a particular
compatible only with certain elastomers, existing tanks glance to the future, it can be observed that the further used
should be changed or replaced. With these adjustments, the thermochemical processes include gasification and pyrolysis
shipping cost per unit volume would be substantially equal to of biomass. The price of hydrogen thus obtained is about three

Fig. 5 e Hydrogen production costs.

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times greater than the price of hydrogen obtained by the Considering, then, the entire cost in USD/km on the life
Steam Reforming process. Therefore, these processes are cycle as the sum of investment costs, the cost per unit of
generally not considered as competitive with those of steam distance relative to the hydrogen fuel cell vehicle (product
reforming. from natural gas) would become even smaller, since, for the
The price of hydrogen from gasification of biomass ranges same cost per kilometer, purchase costs of vehicles with
from 10 to 14 USD/GJ and that from pyrolysis 8.9e15.5 USD/GJ gasoline and methanol fuel cells would be greater [125].
[124]. It depends on the equipment, availability, and cost of That assessment must not be misleading, since the use of
feedstock. Actually hydrogen productions methods can be hydrogen imposes an additional cost to the consumer for the
distinguished into commercial, near term and long term, ac- construction of the production and distribution infrastructure
counting their technological maturity and competitive prices. which is higher than that determined for methanol or gaso-
In this way, steam reforming, partial oxidation, biomass line. Nevertheless, in the long term, hydrogen wins due to
gasification end electrolysis can be considered as commercial. increased efficiency, lower total costs, to lower environmental
Autothermal reforming from hydrocarbons is to be considered impact, the renewability and flexibility in the use of the
as a near term, whereas Plasma reforming, photolysis, ther- source.
mochemical water splitting are to be considered as long Therefore, the methanol will probably be used during the
terms. Electrolysis is still an effective production method and initial phase due to lower infrastructure costs and lower
will be able to guarantee hydrogen availability for a long time vehicle costs compared to those using the Partial oxidation
horizon [124]. technology for the reforming of gasoline.
The transition to hydrogen is expected to be only late and
gradual, with production initially on-site, via steam reforming
Conclusions or electrolysis taking advantage of the existing infrastructure
for the distribution of natural gas and then more and more
The here analysis reported defines some elements that char- centralized, when the economies of scale make for convenient
acterizes the transitional scenario that will lead, in the me- installation of dedicated pipelines.
dium to long term, large scale introduction of hydrogen-
powered Fuel Cell vehicles. In this context, it is again appro-
priate to highlight the unique role and suggestive that meth-
Acknowledgments
anol could play in the transition to a hydrogen economy, in
fact, methanol:
This publication was partially supported by the PON
PON04a2_H “i-NEXT” Italian research program. This work was
1. is more easily transportable and storable than hydrogen or
realized with the contribution of SDES (Sustainable Develop-
natural gas;
ment and Energy Savings) Laboratory e UNINETLAB e Uni-
2. is more easily converted into hydrogen on board the
versity of Palermo.
vehicle compared to gasoline;
3. can be converted into hydrogen at temperatures signifi-
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