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Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Contract No. DE-AC36-08GO28308

Next Generation Hydrogen Stations: 

All Composite Data Products through Fall 2012

S. Sprik, K. Wipke, T. Ramsden, C. Ainscough, and J. Kurtz

Technical Report 

NREL/TP-5600-56809

October 2012
NOTICE

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2

CDP-INFR-01

Hydrogen Dispensed by Quarter

2011Q4 0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Hydrogen Dispensed By Quarter

Hydrogen Dispensed [1000 kg]

 Cumulative Hydrogen Dispensed = 4,600 kg 

0

0.5

1

1.5

2

2.5

Cumulative Amount [1000 kg]

All Sites By Quarter

Cumulative By Site

NREL cdp_infr_01

Created: Mar-20-12 3:25 PM
3

CDP-INFR-02

Histogram of Fueling Rates

0 0.5 1 1.5 2 2.5 3 0

50

100

150

200

250

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

3 minute fill of

5 kg

1,575 Events

Average = 0.72 kg/min

20% >1 kg/min

3% >1.67 kg/min

Reference Line at 1 kg/min

2012 MYPP Tech Val Milestone

NREL cdp_infr_02

Created: Mar-29-12 8:44 AM
4

CDP-INFR-03

Histogram of Fueling Times 

0 2 4 6 8 10 12 14 16 18 20 0

50

100

150

200

250

Time (min)

Number of Fueling Events

Histogram of Fueling Times

Average = 4.72 min

61% <5 min

22% <3 min

 Reference Line at 5 min

 2012 MYPP Tech Val Milestone (5 kg in 3 min)

NREL cdp_infr_03

Created: Mar-29-12 8:45 AM
5

CDP-INFR-04

Histogram of Fueling Amounts

0 1 2 3 4 5 6 7 0

50

100

150

200

250

Amount Fueled (kg)

Number of Fueling Events

Histogram of Fueling Amounts

 Average = 2.95 kg 

NREL cdp_infr_04

Created: Mar-29-12 8:45 AM
6

CDP-INFR-05

Dispensed Hydrogen per Day of Week

Sun Mon Tues Wed Thur Fri Sat 0

5

10

15

20

Dispensed Hydrogen [% of total]

Day of Week

Dispensed Hydrogen per Day of Week

0

10

20

30

40

30 kg/day avg

Daily Average [kg]

All Stations

Individual Stations

NREL cdp_infr_05

Created: Mar-27-12 8:41 AM
7

CDP-INFR-06

Station Capacity Utilization 

1 2 3 0

50

100

150

200

250

Station (Sorted By Increasing Station Capacity)

Capacity Utilization 1 [%]

Station Capacity Utilization

60.8%

Maximum Daily Utilization

Maximum Quarterly Utilization2

Average Daily Utilization2

NREL cdp_infr_06

Created: Mar-21-12 12:00 PM

Note: The focus for early stations

is geographic coverage

1

Station nameplate capacity reflects a variety of system design consderations including system capacity, throughput,

 system reliability and durability, and maintenance. Actual daily usage may exceed nameplate capacity.

2

Maximum quarterly utilization considers all days; average daily utilization considers only days when at least one filling occurred
8

CDP-INFR-07

Station Usage

1 2 3 0

5

10

15

20

25

30

Station (Sorted By Increasing Station Capacity)

Fills Per Day 1

Station Usage

Maximum Daily Fills

Average Daily Fills2

NREL cdp_infr_07

Created: Mar-21-12 12:00 PM

Note: The focus for early stations

is geographic coverage

1

Excludes hydrogen fills of < 0.5 kg

2

Average daily fills considers only days when at least one fill occurred
9

CDP-INFR-08

Time Between Fueling 

<0 0 2 4 6 8 10 12 14 16 18 20 0

1

2

3

4

5

Simultaneous Fills

Back-to-Back Fills

6 % of fills are within 0-5 minutes of each other

82 % of fills have more than 20 minutes between them

725 Total Fills

Time Between Fuelings* [min]

# of Fuelings [% of total]

Histogram of Time Between Fuelings

All Sites Combined

Individual Sites

200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 0

2

4

6

8

10

Final Pressures for Fills with <5 Minutes in Between

# of Fuelings

Final Pressure [bar]

Previous Fill

Next Fill

NREL cdp_infr_08

Created: Mar-26-12 3:48 PM *Time is from end of fill to start of next fill.
10

CDP-INFR-09

Fueling Final Pressures 

200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 0

20

40

60

80

100

120

450 bar*

350 bar Fills (200 to 450 bar) 700 bar Fills ( > 450 bar)

Final Pressure [bar]

Number of Fuelings

Fueling Final Pressures

Avg Final Pressure = 376 bar

% of Fills > 350 bar = 80%

Number of Fills = 435

Avg Final Pressure = 707 bar

% of Fills > 700 bar = 56%

Number of Fills = 1137

Average

Nominal

NREL cdp_infr_09

Created: Mar-27-12 2:53 PM *The line at 450 bar separates 350 bar fills from 700 bar fills. It is slightly over 

the allowable 125% of nominal pressure (437.5 bar) from SAE J2601.
11

CDP-INFR-10

Cumulative Number of Stations

0

1

2

3

4

5

Number of Stations

Reporting Period

Cumulative Stations

NREL cdp_infr_10

Created Mar-20-12 4:45 PM
12

CDP-INFR-11

Hydrogen Stations by Type

0

1

2

3

Compressed Liquid Pipeline Reforming Electrolysis

Number of Stations

Hydrogen Stations by Type

NREL cdp_infr_11

Created Mar-20-12 4:45 PM

Delivered On-Site Production
13

CDP-INFR-12

Fueling Rates 350 vs. 700 bar

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0

20

40

60

80

100

120

140

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

350 vs 700 bar Fills

3 minute fill of

5 kg

Fill Type Avg %>1 %>1.67 Count

------------- ---------- ------- --------- --------

350 bar 0.77 15 3% 406

700 bar 0.71 22 3% 1169

350 bar

700 bar

Reference Line at 1 kg/min

2012 MYPP Tech Val Milestone

NREL cdp_infr_12

Created: Mar-29-12 8:33 AM
14

CDP-INFR-13

Number of Fueling Events per Hour 

0 1 2 3 4 5 6 7 8 9 0

10

20

30

40

50

60

70

Number of Fuelings in an Hour

Frequency [% of total]

Number of Fuelings Per Hour

NREL cdp_infr_13

Created: Sep-25-12 3:07 PM

Average: 1.5 per hour

Median: 1.0 per hour

Max: 7.0 per hour
15

CDP-INFR-14

Hydrogen Dispensed per Hour

0 5 10 15 0

2

4

6

8

10

12

Amount Fueled in an Hour [kg]

Frequency [% of total]

Hydrogen Dispensed Per Hour

NREL cdp_infr_14

Created: Sep-25-12 3:07 PM

Average: 4.1 kgs per hour

Median: 3.5 kgs per hour

Max: 14.9 kgs per hour