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TECHNOLOGY
DATASHEETS
ELECTRIC
SCOOTERSwith Fuel Cell Range Extender
BENEFITS
FEATURES
SPECIFICATION
Zero emission vehicle
Extended driving range
Fast hydrogen refueling
Comfortable driving
Noiseless operation
High efficiency of fuel
conversion
Safe and easy operation
DESCRIPTIONHySa Systems, in collaboration with the South African Post Office (SAPO), converted three E-max scooters that were previously operated by SAPO into a hybrid type battery dominant hydrogen fuel cell vehicle. The lead acid battery was replaced with a more energy dense and lighter lithium ion battery pack coupled with a fuel cell system acting as range extender.
The on-board hydrogen storage was developed to be interchangeable, quick connect cartridges. The advantage of using this technology reduces the volume needed to store the required hydrogen on-board the scooter, but also potentially eliminates expensive refuelling infrastructure where the scooters are charged overnight as well as ensuring flexible and convenient refuel locations.
The benefits of the scooter conversion include increased performance in terms of range and efficiency increases as well as producing zero emissions at point of use and the potential to decarbonise the operation of the fleet completely.
4 kW electric motor
144 Ah Lithiumion battery pack
1 kW PEM fuel cell range extender
2x interchangeable MH hydrogen storage tanks
1500 SL hydrogen storage capacity
Up to 210 km driving range
ELECTRIC SCOOTER
FUEL CELL RANGE EXTENDER
HYDROGEN STORAGE AND REFUELLING STATION
Scooter model E-max 110S
Max speed 75 km/h
Motor power and type 4 kW Brushless electric motor
Battery pack Lithiumion battery DC 48V, 144 Ah, 5 kWh
Range 210 km (varies with riding conditions)
Scooter / battery weight
190 kg / 60.8 kg
Fuel cell typeAir-cooled, open cathode, self-humidified
LT-PEMFC
Peak / nominal power 1100 W / 1000 W
Stack nominal current 33.5 A @ 30 V
Stack DC voltage 25 – 48 V
Reactants 99.99 % dry hydrogen and air
Hydrogen consumption
at nominal power12.5 SLPM
Operating pressure / temperature
0.50 – 0.65 bar / < 65 oC
Stack dimensions 264 mm x 203 mm x 104 mm
System weight less than 6.8 kg
Storage method 2x Air-cooled SS MH tanks
Metal hydride material AB2 Alloy
Hydrogen storage capacity
~ 1500 dm3 at STD
Operating pressure / temperature
<30 bar / 100 oC
Hydrogen off-board charge time
180 mins
Quick connect coupling
Swagelok QM series
Tank dimensions Diameter
110 mm Length 780 mm
Tank weight / MH material weight
14.5 kg / 5.5 kg
METAL HYDRIDE
TANKS for Hydrogen Storage and Supply
BENEFITS
FEATURES
H storage capacity range: from 10 NL
to 20 Nm3
H2 charge pressure (T=20 oC) [bar]: >10
H2 discharge temperature
(P>1 bar) [oC]: >0
Customized solutions upon
customer’s requirements
Safety and reliability
Compactness Simplicity in design, operation
and service
Flexibility in size, layout and H2
output flow rates
DESCRIPTIONHySA Systems has developed a series of metal hydride hydrogen storage tanks for various applications including hydrogen supply to small and medium size fuel cell stacks
The tanks allow for compact and safe hydrogen storage at standby pressure below 10 bar and its further supply to a consumer using flow of ambient air, or circulation of a liquid (T=10 – 40 oC) for the heating (discharge) and cooling (charge).
SMALL-SIZE AIR HEATED / COOLED UNITS
MEDIUM- AND MEDIUM-LARGE SIZE UNITS
HySA-MH-10 HySA-MH-90
H storage capacity [NL] 10 90
MAX output H2 flow rate [NL/min]
0.5 1.5
Gas connection Schrader valve Quick coupling
Size [mm] Ø25 x 100 Ø38 x 226
Weight [g] 160 830
Applications Laboratory, educational kits
HySA- MH-1K
HySA- MH-1.9K
HySA- MH-10K
HySA- MH-20K
Heating / cooling
Air Liquid Liquid Liquid
H storage capacity [Nm3]
1 1.9 10 20
MAX output H2 flow rate
[L/min STP]14 20 170 170
Charge time (20 oC) [min]
60 (40 bar H2)
45 (40 bar H2)
10 (185 bar H2)
15 (100 bar H2)
Size [mm]600 x 140
x 70Ø115 x 1060
950 x 120 x 700
800 x 1000x 2 00
Weight [kg] 14 30 250 1200
Applications FC scooter FC golf cart FC forklift FC forklift
FUEL CELL
FORKLIFT Locally designed and built fuel
cell power system with solid
state hydrogen storage
(Metal Hydride Technology)
BENEFITS
FEATURES
H2 charge pressure 100 – 185 bar
H2 storage capacity ~20 Nm3
H2 refueling time 15 minutes
Full-load operation
(VDI-60) duration ~3 hours
Zero emissions No necessity for battery recharge /
replacement
Simple infrastructure for
H2 refuelling
Safe operation and service
DESCRIPTIONIn 2019, HySA Systems at the University of the Western Cape commissioned a locally designed and built fuel cell power system integrated with a 2nd generation solid state hyrogen storage system. The power module replaces the incumbent lead acid battery technology significantly increasing operating performance of a STILL RX60-30L 3-ton electric forklift. Unlike commercially available systems, the unit utilises Metal Hydride technology with increased operating safety due to lower operating pressures. Sufficient counterbalance for the STILL Forklift is also achieved as a result of the Metal Hydride technology. The Metal Hydride technology operates at 100 – 185bar yet still provides the equivalent amount of fuel on-board as a 350bar commercial system. This feature further offers the advantage of a lower cost refueling solution to be implemented.
SPECIFICATIONFuel Cell Power module
700kg
MH tank 1150kg
TOTAL
1850kg
FC FORKLIFT WITH MH H2 STORAGE EXTENSION TANK
Parameter Rating / Dimension
Overal Dimension 840mm (L) x 1010mm (W) x 777mm (H)
Weight of Unit 1850kg
H2 Storage Metal Hydride
H2 Capacity 20Nm3
Battery Terminal Voltage 80Vdc Nominal (80.5V – 95.2Vdc)
Battery Cemistry Sealed Lead Acid
Battery Capacity 8.4kWh (7 x 100Ah @ 12Vdc)
Ultra Capacitors Maxwell
Ultra Cap Capacity 83.3 Farad @ 97.2V (36x 2.7V)
Fuel Cell Ballard, 14.3kW, 48V@300A
Full Load
Automotive 9SSL/ 75cell, Water Cooled, Closed Cathode
LT PEM Fuel Cell
Anode H2 Consumption 150slpm H2 @ 300A
Cathode Air consumptiom 850slpm Air
Fuel Cell Operating Temperature 60 deg C
Module Average Power 11kW
Module Peak Power 30kW
BOP Power Consumption at 300A 3.5kW
DC-DC Boost Converter 15kW / 48 to 96Vdc Boost
Fuel Cell CVM System 25 Cell Onboard with isolated channels and
embedded processor
Inter device Communications Automotive CAN (CAN OPEN) and Industiral
Modbus 485/TCP
User Interface Graphical Interface on Tablet or PC via Wifi
System Control Fuel Cell Management 32 Bit: Industrial PLC, Converter and Instrumentation: 32 Bit ARM
Processor
Remote Monitoring and Access Full Access via GSM, Remote Diagnostic, In field remote firmware update and Data /
Event Logging
METAL HYDRIDE
HYDROGEN
COMPRESSORS
BENEFITS
FEATURES
Thermally driven: no
moving parts
Number of stages: 1 to 3
H2 compression ratio per a
stage: 5 – 10
Cooling: running water
Heating: electric,
pressurized water, steam
Safety and reliability
Simplicity in design, operation
and service
NoiselessFlexibility in size
and layout
Utilization of waste heat
DESCRIPTIONIn 2008 – 2020, South African Institute for Advanced Materials Chemistry (SAIAMC) and HySA Systems at the University of the Western Cape developed a series of novel metal hydride (MH) hydrogen compressors allowing for the compression of hydrogen without any moving parts.
The compressors are thermally-driven and only require cooling and heating to provide the required compression of hydrogen. The process is based on lower temperature / low-pressure H2 absorption followed by higher temperature / high-pressure H2 desorption. The H2 compression ratio varies from 5 to 10 per stage, and aligning the operation pressure range to customer’s specification is achieved by a proper selection of the MH materials.
The compressors are build upon advanced engineering solutions patented in South Africa, Russia and China.
SPECIFICATIONOutput H2 PURITY
99.99+%
Suction pressure down to 3 bar
Discharge pressure up to 200 bar (500 bar for
prototypes)
Productivity range from 0.06 to x10 Nm3 H2 / h
PLC-based control & datalogging system
Customized solutions upon customer’s
requirements
123
METAL HYDRIDE HYDROGEN COMPRESSORS
SA-MHC- 7/200-0.06
SA-MHC- 10/200-1
SA-MHC- 3/200-5
SA-MHC- 50/200-15
Numbe r of stages 2 2 3 1
Suction pressure [bar] 7 10 3 50
Discharge pressure [bar]
200 200 200 200
Productivity [Nm3/h] 0.06 1 5 15
Cooling (T [°C]) Water
(15–25) Water
(15–25) Water
(15–25) Water
(15–25)
He ating (T [°C]) Electric (130)
Steam or pressurised water (140)
Steam (140) Steam (140)
LT-PEM STACKS FOR
UAV & SCOOTER
APPLICATIONS
BENEFITS
FEATURES
Safe and easy maintenance and
operation
Operating temperature
5 to 50 oC
Maximum altitude ~ 3000 m
System lifetime ~ 1000 hrs
Refuelling time of a
few minutes
Flight duration of over three times longer than that
achieved by battery operated UAVs
Can offer double the range of battery operated scooters
Have a higher energy to mass
ratio than battery-based
systems
DESCRIPTIONSince 2008 HySA Systems hosted by South African Institute for Advanced Materials Chemistry (SAIAMC) at the University of the Western Cape has been actively involved fuel cell technology research, with specific focus on the integration of fuel cell power modules into various systems. In 2018 HySA Systems developed their first in-house LT-PEM short fuel cell stack for UAV applications.
HySA Systems offers an air cooled polymer electrolyte membrane fuel cell stack, utilising H2 and forced air convection of ambient air to provide an environmentally friendly source of DC power. The process is based on the electrochemically catalysed reaction between H2 and air to produce electricity and water. HySA Systems LT-PEM stack has been developed with advanced open cathode technology. These stacks can be scaled up to meet power requirements from 250 W to 1 kW and integrated into various end user applications such as UAVs and scooters.
DR SIVAKUMAR PASUPATHIDIRECTOR: HYSA SYSTEMS COMPETENCE CENTRE
ASSOCIATE PROFESSOR:SAIAMC
UNIVERSITY OF THE WESTERN CAPE
TEL: +27 (0) 21 959 9318
EMAIL: [email protected]
WEBSITE: WWW.HYSASYSTEMS.COM