Session C9 Mechanical Engineering Topics 9 6267 Disclaimer—This paper partially fulfills a writing requirement for first year (freshman) engineering students at the University of Pittsburgh Swanson School of Engineering. This paper is a student, not a professional, paper. This paper is based on publicly available information and may not provide complete analyses of all relevant data. If this paper is used for any purpose other than these authors’ partial fulfillment of a writing requirement for first year (freshman) engineering students at the University of Pittsburgh Swanson School of Engineering, the user does so at his or her own risk. Climate change is a reality we have ignored for years. Consequently, we are facing global shifts in weather patterns and worldwide temperature changes. The Intergovernmental Panel on Climate Change agrees that “the massive increases of CO₂ and other greenhouse gases (GHG) will increase overall average global temperatures and cause climate change.” And although CO₂ is less damaging than other greenhouse gases, “it is thought to contribute between 60% and 70% to global climate change, because of its sheer volume” in our atmosphere [1]. Even more staggering, is that the United States is the second largest contributor to CO₂ emissions, emitting 5.6 Gt of CO₂. Combine that number with the number one contributor, China at 8.3 Gt, and together, China and the United States “emit more than 40% of the global carbon dioxide” emissions worldwide (see Table 1). According to Carol Dahl, the buildup of CO₂ in our atmosphere is “indisputably coming from human-made sources”; and about 80% from burning fossil fuels for electricity [1]. And those percentages are only expected to rise. FIGURE 1 [3] Table showing CO₂ output for various countries. HYDROGEN FUEL CELLS AND THEIR APPLICATIONS IN THE BMW I8 Hannah Schell, hes62@pitt.edu, Mahboobin, 10:00, Claire Walsh, clw115@pitt.edu, Vidic 2:00 Abstract-To combat Earth’s finite quantity of fossil fuels, in 2008, the U.S. government began funding research regarding hydrogen as an alternative fuel to natural gas and crude oil. Using hydrogen fuel cells, such as the BMW I8, instead of the traditional gasoline powered engine is important, because reducing the amount of net carbon emissions to a scintilla or nothing at all will, ultimately, reduce our impact on our environment. In order to obtain energy from hydrogen fuel, we need to “undo” the process of photoelectrochemical water splitting, or the way we originally obtain the hydrogen fuel. To do this, the fuel cell requires O2 and H2 as reactants to produce H2O and electricity. The process happens within an electrode battery combination and, ultimately, produces a usable electric circuit. As more of these fuel cells are stacked, a larger circuit is created and thus, more power is available. Hydrogen fuel cell vehicles are some of the lowest emission vehicles and most efficient compared to the hybrid and electric car, and are therefore major competitors. However, without a commercial implementation of these vehicles, such technologies cannot reach their full potentials. One developing commercial hydrogen fuel cell vehicle is the BMW I8. It is within this essay that we will discuss how this vehicle works, why it is effective, why we believe it is important that vehicles similar to the BMW I8 should be implemented/marketed commercially, and what the drawbacks and the implementations of this vehicle are. Through the employment of a hydrogen powered fleet, we could minimize the volume of carbon released; reduce our dependency on foreign oil; lower fuel costs; and make transportation cleaner and more efficient. Since 1850, the total energy production and use has increased from “0.2 billion tons of equivalent oil to 11.4 billion tons of equivalent oil” in 2005. It is also predicted that global demand for energy will increase anywhere between “27% and 61% by 2050. However, if we continue to heavily rely on cheap fossil-fuel-intensive electricity generation in the shortterm, we will leave ourselves with less adaptability to other technologies in the future. Sustainable energy use is the Keywords –BMW Hydrogen 7, BMW I8, Hydrogen fuel cells, Hydrogen fuel cell cars, Hydrogen I8 prototype Hydrogen vehicles University of Pittsburgh Swanson School of Engineering 2016-03-04 1 Hannah Schell Claire Walsh solution to this dilemma. The following table provides energy data about the top 20 Energy Sustainability Index countries. ESE is defined as energy security or the “effective management of primary energy supply...the reliability of energy infrastructure, and the ability of energy providers to meet current and future demand.” EQ is energy equity which “contains indicators about the accessibility and affordability of energy supply across the population.” ESU stands for environmental sustainability and “is related to energy efficiency at the supply and demand ends as well as energy supply from renewable and other low-carbon sources”. As expressed by the numbers in the table, the U.S. is ranked 15th with a 9.14/10.00 or “A” in energy security, a 10.00/10.00 or “A” for energy equity, and a 3.35/10.00 or “C” for energy sustainability. Comparing the scores of the United States to the leading countries’ scores such as Switzerland, we find that along with a 10.00/10.00 in sustainability and efficiency, high scores in energy security and energy equity are also attainable. It will be a challenge to assure an “environmentally sustainable, reliable, affordable, and socially acceptable” energy, but we can infer that if Switzerland did it, so can we [7]. Part of that solution must be hydrogen fuel, fuel cells, and hydrogen fuel cell vehicles. Alternative energy used in vehicles has evolved immensely over the years. Starting from the traditional petroleum usage becoming the United States’ most used fuel in the 1950’s (with little to no consideration of alternative energy) to solar energy, natural gas and hydrogen power becoming growing contenders in recent years [5]. In 2014, President Obama recognized the potential for hydrogen to become a major transportation fuel source and the US Department of Energy began heavily funding companies such as FedEx Express and the Center for Transportation and the Environment to research this viability. By funding these companies, commercial use of hydrogen has been implemented as a fuel in controlled and monitored environments like in airports and delivery transportation systems. Success was accelerated. It is now estimated that “the primary energy demanded by the transportation sector will increase from 2470 mToe in 2008 to 3578 mToe in 2035” and that the energy demanded in the form of hydrogen in 2035 is likely to double or even triple to somewhere between 42.4 and 98.9 million tons, as “the transportation sector is one of the most likely areas of application of hydrogen” [2]. However, in 2014, an IEEE published article highlighted that while hydrogen is “abundant, renewable and non-polluting”, it is still “30 percent more expensive to carry the hydrogen via pipelines than to carry natural gas” [8]. In addition, while 1 kilogram [2.2 pounds] of hydrogen has an equivalent amount of energy as 1 gallon of gasoline does, the large volume and density of hydrogen make it difficult to store a large amount in a compact space to achieve an equivalent driving range of a traditional vehicle [alt fuels data ctr]. However, these numbers, as Luis Gandia points out, are “conservative” and that while this specific outlook looks challenging it is “not impossible, especially if there is a dynamic market stimulating the production and consumption of hydrogen” [2]. For this reason, at this point in time, it is impractical to use hydrogen as a transportation fuel source when there is a more cost efficient alternative. Solutions to these drawbacks will have to come through more research, a stronger infrastructure, more marketing, and ultimately, more funding. Hydrogen can be obtained through numerous different processes, including natural gas reforming, coal gasification, and biomass gasification. However, one of the only processes that emits little to no harmful byproducts, such as carbon dioxide, is photoelectrochemical (PEC) water splitting. Within this process itself there are at least four different variations. However, speaking in general terms, in order for this process to be effective, a system similar to a photovoltaic panel must be set up. The process begins as UV rays from sunlight hit the anode and supply the surrounding water molecules from the electrolyte with energy. Once the molecules accumulate enough energy to overcome the activation energy required by the first half reaction provided below, the bonds between the hydrogen and oxygen atoms break to form oxygen gas, hydrogen ions, and electrons. The FIGURE 2 [5] Table showing various countries’ energy security, energy equity, and environmental sustainability. HYDROGEN AS A FUEL SOURCE 2 Hannah Schell Claire Walsh oxygen gas (O2) bubbles off to be collected at the surface, while the hydrogen ions and electrons go through another half reaction at the cathode. Since hydrogen ions are simply individual protons with one attached neutron, they carry an equal but the opposite charge as electrons and bond together to form hydrogen gas according to the second equation listed below. 2H2O + 1.23V→ 4H+ +2 O2 +4e4H+ + 4e- => 2H2 PEC water splitting is classified as a “long-term technology pathway”, because it offers the “potential for high efficiency output at low operating temperatures using cost effective materials” [energy.gov ]. However, improvements still need to be made with the efficiency, durability, and costs of the reactor and process. For example, the National Renewable Energy Laboratory developed their own PEC system that produces hydrogen at a 12.4% solar-to-hydrogen conversion efficiency. This is the main reason easier and cheaper options such as natural gas reforming will continue to dominate the hydrogen production industry [nrel]. with the electrons and oxygen ions to form water and heat. A single MEA produces a minimal amount of electricity so hundreds of cells must be stacked and connected in series to produce a sufficient output of electrical current [systems]. HYDROGEN FUEL CELLS In recent years, vehicle improvement consists mostly of efficiency and sustainability. With this focus, fuel cell vehicles were created. Fuel cell vehicle research has mostly consisted of polymer electrolyte membrane (PEM) fuel cells. Generally put, PEM fuel cells (the current research focus) use the chemical energy stored in hydrogen to cleanly and efficiently produce water, heat, and electricity [fuel cell.gov]. A PEM fuel cell has three main components that make this conversion possible: the membrane electrode assembly (MEA), bipolar plates, and gaskets. Within the MEA itself, there is a polymer electrolyte membrane (PEM), catalyst layers, and gas diffusion layers (GDLs) pictured in the figure below. The PEM is a semipermeable plastic wrap like material that allows protons to pass through, but not electrons. The catalyst layers consist of an anode, or negatively charged, layer and a cathode, a positively charged, layer that are placed on opposite sides of the electrolyte. The GDLs are made of sheets of carbon paper and are placed outside of the catalyst layers. Two bipolar plates made of metal surround each cell in the stack of MEAs so electricity can be conducted between cells and physical durability can be added to the stack. Gaskets, made of a “rubbery polymer”, are placed in between two bipolar plates and around the MEA to provide “a gas-tight seal” [parts]. The entire process commences when hydrogen fuel and oxygen gas, in the form of air, are fed in through the GDLs. From here, hydrogen reacts with the negatively charged anode catalyst layer to form hydrogen ions and electrons while oxygen reacts with the positively charged cathode catalyst layer to form oxygen ions. The electrons create a current, move from the anode catalyst layer, pass through a battery and end at the cathode catalyst layer. The hydrogen ions are guided through the PEM to the cathode catalyst layer where they react FIGURE 3 [4] As previously discussed, the transportation sector is the most likely area to apply hydrogen as a fuel. But, according to Luis Gandia, only light duty vehicles will be considered for fuel cell application. We can analyze the efficiency of the overall process from producing hydrogen fuel to when it is converted into electricity to power the fuel cell vehicle. To start, energy is lost in every step of the hydrogen to vehicle propulsion process: “production, storage, distribution, delivery and end use.” Gandia reports his own findings which state that producing hydrogen fuel has an overall 75% efficiency when converting electricity from AC/DC to feed the water electrolyzer. Within the hydrogen delivery process, assuming an average compression of 25 Mpa of the hydrogen gas, the efficiency is 72%. When the actual efficiency of the fuel cell is about 50% and the efficiency in which the fuel cell operates is assumed to be 90%, the overall efficiency is estimated to be only 23% [luis]. However, when comparing these numbers to the Fuel Cells Technology Program of the U.S. Department of Energy, a PEM fuel cell yields 60% efficiency for transportation, not 50%. Therefore, the overall efficiency will increase to about 28% [energy.gov]. HISTORY OF ALTERNATIVE ENERGY IN BMW VEHICLES BMW’s First Hydrogen Car 3 Hannah Schell Claire Walsh In 2005, BMW released the Hydrogen 7, claiming it to be the first production hydrogen vehicle. There were only 100 ever produced, making them very rare to own. During the design phase, German researchers caught a major breakthrough in hydrogen technology. Hydrogen gas has a very low density, which would mandate a massive fuel tank compared to a standard gasoline powered vehicle. Based off of an existing production diesel engine, BMW technicians were able to design a new cylinder head for hydrogen power [10]. By using computational fluid dynamics, essentially calculating how hydrogen will flow most efficiently, a new combustion chamber was designed for the engine for maximum power output. Researchers who collaborated with BMW developed a high pressure injection system with would now be able to pump hydrogen into the combustion chamber at a pressure of about 4500 pounds per square inch (psi). Furthermore, they also found that a combination of spark and hot surface ignition of the vehicle would produce the maximum efficiency for the car. Through all of these changes to the standard diesel engine, the efficiency of the fuel cell was augmented to 42 percent, comparable to a standard turbo-diesel engine [11]. The increase in efficiency of the hydrogen is what allows us to have fuel tanks small enough where there is no need to supplement the vehicle with a gasoline tank. BMW’s Current Hydrogen Fuel Cell The Hydrogen 7 was BMW’s first attempt at creating a completely hydrogen powered vehicle. While it was a success in terms of scientific achievement, there were only 100 ever produced as a way of establishing a name for BMW in the energy conservation market. Currently, the company is producing a hydrogen powered model of their i8 supercar. What this promises is that BMW will release highly efficient and ecologically conservative luxury vehicles to the general public, which will lead to the popularization of low emissions vehicles. While they may have been the first to release the technology, many other automotive companies are also developing their own hydrogen fuel cells to power their vehicles. The globalization of clean energy would greatly reduce the volume of carbon dioxide gas released into the atmosphere as a result of traditional internal combustion engines. BMW model. The low-weight carbon fiber design makes it aerodynamic and energy efficient. FIGURE 4 [1] The current prototype for the i8 hydrogen was built in 2012 [6] and is powered entirely by a hydrogen fuel Cell [Figure 2]. The fuel tank will be located under the body of the vehicle towards the center. This is connected to the hydrogen fuel cell which then powers the motor [Figure 3]. The fuel cell, as described previously, strips the hydrogen atoms of a single electron, then produces water vapor and electricity as a byproduct. The electricity flows through into the motor where the electric energy is turned into mechanical energy via a pulsating rod. When electrons pass into the motor they encounter a rod. The current through this specially designed rod turns an axle which provides the energy to turn the wheels, propelling the vehicle either forwards or backwards [9]. While the Hydrogen 7 enabled the driver to choose between gas, hydrogen and hybrid, the i8 Hydrogen runs exclusively on a hydrogen fuel cell. BMW i8 The i8 was originally designed as a luxury hybrid vehicle aimed to become a pioneer in the electric car market. The hybrid model ran on a combination of petroleum and electricity. While driving without the use of the electric motor, the battery is charged directly by the petroleum engine. The battery receives power whenever the driver engages the brakes, regardless of whether the car in hybrid mode. The mechanical energy from the brake pads is converted into electrical energy and then stored in the battery for later usage [11]. The i8 also boasts the lowest center of gravity of any FIGURE 5 [2] Image of the hydrogen fuel tank, shown in blue, the hydrogen fuel cell, shown in orange, and the motor shown in green. 4 Hannah Schell Claire Walsh identified as the need for cost reduction, which requires a substantial increase in R&D investments, and policy support, because hydrogen is generally not on the agenda of the ministries responsible for environment protection and energy security. The roadmap objectives for 2050 include 80% of light-duty vehicles and city buses fueled with CO₂-free hydrogen, reaching more than 80% CO₂ reduction in passenger car transport and the use of hydrogen in stationary end-use applications in remote locations and island grids. As a consequence of this roadmap, a Fuel Cells and Hydrogen Join Technology Initiative was established as a European public/private partnership for hydrogen and its end-use applications.54The Hydrogen and Fuel Cells Program Plan outlines the strategy, activities and plans of the U.S. Department of Energy Hydrogen and Fuel Cells Program.55 This document was completely revised in September 2011 after its previous update in 2006; by that year, it was known as the Hydrogen Posture Plan. The new program seeks to act as a catalyst in the transition from R&D to demonstration and early deployment of hydrogen by integrating real-world technology demonstrations, public outreach and education and market transformation activities. To this end, a detailed technology development timeline and key milestones are established between 2010 and 2020 in the areas of fuel cell R&D, hydrogen production, delivery and storage, manufacturing R&D, technology validation, education, safety, codes and standards, market transformation and system analysis” [2]. Where are the Hydrogen Cars Hydrogen powered vehicles are clean and efficient. If designed properly, they release zero emissions into the atmosphere. Looking at a well-traveled highway today, there would be a very small number of hydrogen fuel celled vehicles you come in contact with. This can be largely attributed to the high cost of owning and maintaining Hydrogen Fuel celled vehicles. The cars themselves are expensive, Toyota’s Mirai is the most affordable option, costing a staggering $50,000. The BMW I8, as is the nature of supercars, will cost over $100,000 [8]; too much money for the average middle class worker. Assuming one can afford this, therein lies the problem of filling your car with hydrogen. There are only a few small Hydrogen fueling stations that are located almost exclusively in California, which limits the customer base to only a few wealthy Californians who are interested in saving the planet. Electric and hybrid (combination of electric and gasoline) powered vehicles have a much stronger grip on the market base. Almost every person living in the United States has electricity in their homes; it is a widely available resource, and it’s much less expensive than gasoline. What this indicates is that if oil and gasoline companies invest in popularizing hydrogen fueling stations, more people will consider buying hydrogen vehicles and thus lead to both the popularization of hydrogen cars and consequently improvements in the fuel cell itself. HYDROGEN WORLDWIDE DOWN THE LINE Production of hydrogen powered vehicles will have a substantial effect on the volume of CO₂ emitted by humans. Commercialization is the key to popularizing the technology to the point where it is affordable enough for everyone to own a hydrogen powered vehicle and thusly reduce carbon emissions due to transportation to almost nothing. BMW has paved the way before with their Hydrogen 7 model and will continue to break barriers with the i8. While other models may be more affordable, none can match the efficiency of the i8 due to the improvements made on their fuel cell. Preliminary data from the International Energy Agency (IEA) indicate that global emissions of carbon dioxide from the energy sector stalled in 2014, marking the first time in 40 years in which there was a halt or reduction in emissions of the greenhouse gas that was not tied to an economic downturn [4]. Global emissions of carbon dioxide stood at 32.3 billion tons in 2014, unchanged from the preceding year. The IEA data suggest that efforts to mitigate climate change may be having a more pronounced effect on emissions than had previously been thought [4]. Hydrogen fuel cell technology is expected to undergo major advancements during the next few decades. It is predicted that by 2050, 80% of small commercial vehicles and public transportation busses will be fueled by hydrogen [2]. “As it has been demonstrated for the renewables, the deployment of hydrogen will likely fail without governmental support. Main initiatives in this regard correspond to the European and U.S. authorities. HyWays is the name of the European hydrogen energy roadmap.53 this roadmap was designed with the aim of helping to overcome the economic, technological and institutional barriers that make the introduction of hydrogen in the energy system difficult. One of its drivers is the fact that the possibility of taking a leader position in the worldwide market for hydrogen technologies would provide new economic opportunities and strengthen European competitiveness. The main challenges were REFERENCES [1] Dahl, Carol. "12." International Energy Markets Understanding Pricing, Policies, and Profits. 2nd ed. N.p.: PennWell, 2015. N. pag. Print [2] Gandia, Luis M., Gurutze Arzamedi, Pedro M. Dieguez, and Luis M. G. "1." Renewable Hydrogen Technologies: Production, Purification, Storage, Applications and Safety. N.p.: Elsevier, 2013. N. pag. Print. [3] Gandia, Luis M., Gurutze Arzamedi, Pedro M. Dieguez, and Luis M. G. "18." 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International Energy Markets Understanding Pricing, Policies, and Profits. 2nd ed. N.p.: PennWell, 2015. N. pag. Print [4] Major components of an American Honda Motor Corporation FCV. www.fueleconomy.gov. U.S. Department of Energy, (Online digital image). <http://www.fueleconomy.gov/feg/fuelcell.shtml> [5] Thomas, Ken D. "6." Handbook of Research on Sustainable Development and Economics. N.p.: IGI Global, 2015. N. pag. Print. ACKNOWLEDGEMENTS We would like to thank everyone who has helped us accomplish writing this research paper: Amanda Brant for providing helpful feedback on the specificity of our topic; the writing center for engineers for providing such detailed and helpful instructions to follow; Jacalynn Sharp for giving support, guidance, and constructive criticism; and our families for always there for us. SOURCES CONSULTED 6