Hydrogen can contribute significantly to reducing emissions from the transport sector, as it is particularly well suited as a fuel for heavy-duty transport. Sampling systems and methods have already been developed for use at hydrogen refuelling stations for light-duty vehicles (700 bar, < 60 g/s), but technical evidence is lacking for heavy-duty transport (350 bar, > 60 g/s). The MetHyTrucks project aims to provide the necessary data for standardising the sampling of hydrogen at refuelling stations for heavy-duty vehicles.

With the increasing interest in the use of hydrogen and fuel cells in medium and heavy duty vehicles, the need for specific standards for these applications has increased. There are currently about 500 hydrogen-powered buses, trucks and trains in Europe, but this number is expected to grow very quickly. By 2030, there could already be more than 60,000 hydrogen-powered trucks in operation. This requires a large infrastructure with hydrogen refuelling stations suitable for trucks.

Hydrogen-powered fuel cell vehicles require extremely pure hydrogen, as some impurities can affect fuel cell performance even at very low levels. Previous metrology projects have paved the way for the development of the European quality infrastructure for hydrogen conformity assessment. However, the reliability of a measurement is inextricably linked to the representativeness and reliability of the sampling itself. Poor sampling can result in an entire fleet of heavy-duty vehicles being damaged. Furthermore, standardisation is needed as the heavy-duty hydrogen fuelling network is shared between different operators (e.g. BP, Air Liquide, MotiveFuels). Sampling procedures should also not lead to quality differences within the emerging network.

The ZBT regularly carries out sampling at hydrogen filling stations with the sampling system Hy-SaM, which it developed itself. Accordingly, extensive experience has been gained with regard to the procedures for preparing, carrying out and analysing the sampling while ensuring plant safety.

In the consortium, necessary adaptations for the heavy-duty application are jointly worked out on the basis of the sampling systems used. This applies both to the selection of necessary hardware that fits the connections and geometries in the heavy-duty area and to the creation of strategies and guidelines for representative and safe sampling. Elementary here is the determination of the effect on the sample due to the changed physical boundary conditions during refuelling (especially pressure and mass flow).

In a later project phase, samples will be taken with the adapted systems, including the Hy-SaM, at heavy-duty fuelling stations (including the ZBT hydrogen test field) and analysed in the hydrogen quality laboratories (in ZBT's Hy-Lab and others). The methods used are checked and validated. By publishing the developed systems, protocols and methods, the project will be able to assist in the development of standards towards safe and representative H2 sampling in the heavy-duty sector.

Consortium:

• CESAME
• CMI
• ENGIE
• GERG
• PTB
• RISE
• SINTEF
• VSL
• ZBT

Short title: MetHyTrucks
Duration: 1 June 2023 - 31 May 2026
Funding: EURAMET e.V., European Partnership
Details

Department Hydrogen Infrastructure
Contact: s.kaiser(at)zbt.de