Design of a Fuel Cell Laboratory
(2024) MVKM05 20241Department of Energy Sciences
- Abstract
- The thesis focuses on the design of a laboratory setup for a 100 kW fuel cell system, intended for heavy-duty vehicle applications. The increasing interest in Proton Exchange Membrane (PEM) fuel cells as a viable alternative for long-haul transport stems from the limitations of battery-electric vehicles, particularly due to the weight and energy density constraints of current battery technologies. Hydrogen, with its significantly higher specific energy compared to lithium-ion batteries, presents a promising solution for electrifying long-range transportation. However, the use of hydrogen in an enclosed space poses greater safety risks than in an open area. Therefore, the primary objective of this project is to develop safe strategies for... (More)
- The thesis focuses on the design of a laboratory setup for a 100 kW fuel cell system, intended for heavy-duty vehicle applications. The increasing interest in Proton Exchange Membrane (PEM) fuel cells as a viable alternative for long-haul transport stems from the limitations of battery-electric vehicles, particularly due to the weight and energy density constraints of current battery technologies. Hydrogen, with its significantly higher specific energy compared to lithium-ion batteries, presents a promising solution for electrifying long-range transportation. However, the use of hydrogen in an enclosed space poses greater safety risks than in an open area. Therefore, the primary objective of this project is to develop safe strategies for hydrogen supply, ventilation of exhaust purge gases, and leak detection mechanisms within the closed laboratory environment. The project methodology primarily involves conducting a Design Failure Modes and Effects Analysis (DFMEA) to identify potential safety risks, followed by the design of safety measures. The design process integrates knowledge from regulations, existing industry standards and inhouse knowledge used for building the hydrogen system used in combustion engine test cells at the department of energy sciences, LTH, thereby ensuring the safe operation of the fuel cell system. The outcome of this thesis will provide a robust laboratory infrastructure, enabling future research and development in fuel cell technology for heavy-duty vehicles. (Less)
- Popular Abstract
- As the world seeks alternatives to fossil fuels, hydrogen fuel cells are emerging as a promising solution, especially for hard-to-decarbonize sectors. This study focuses on heavy-duty vehicles requiring long ranges. This thesis presents the design of an advanced hydrogen fuel cell laboratory at Energy science department, LTH, Lund University, with a focus on safety. While hydrogen offers significant advantages as an energy carrier, it also presents challenges, such as a wide flammability range and its ability to diffuse through materials. These challenges become more critical when using hydrogen in confined lab spaces, where leaks can accumulate.
A proactive risk assessment process called Design Failure Modes and Effects Analysis was... (More) - As the world seeks alternatives to fossil fuels, hydrogen fuel cells are emerging as a promising solution, especially for hard-to-decarbonize sectors. This study focuses on heavy-duty vehicles requiring long ranges. This thesis presents the design of an advanced hydrogen fuel cell laboratory at Energy science department, LTH, Lund University, with a focus on safety. While hydrogen offers significant advantages as an energy carrier, it also presents challenges, such as a wide flammability range and its ability to diffuse through materials. These challenges become more critical when using hydrogen in confined lab spaces, where leaks can accumulate.
A proactive risk assessment process called Design Failure Modes and Effects Analysis was employed to identify potential failure points and design deficiencies. Key safety measures include pressure relief valves, flow restrictors, a fume hood, hydrogen sensors, and a ventilation system to prevent hydrogen buildup. All these features work together to create a controlled environment where researchers can safely explore and advance fuel cell technology.
This project, grounded in practical industry knowledge and multiple facility visits, ensures that the lab not only meets academic research needs but also adheres to stringent safety standards. While the design prioritizes safety, the study also highlights various challenges that need to be addressed, such as proper work procedures, inspections, and installation, as well as the potential for unforeseen risks. The final design represents a significant contribution to the ongoing shift toward sustainable energy solutions, creating a safe space for future fuel cell research. (Less)
Please use this url to cite or link to this publication:
http://lup.lub.lu.se/student-papers/record/9174211
- author
- Harikumar, Sidharth LU
- supervisor
- organization
- alternative title
- Designing a safe hydrogen fuel cell laboratory for the future of sustainable energy
- course
- MVKM05 20241
- year
- 2024
- type
- H2 - Master's Degree (Two Years)
- subject
- keywords
- Hydrogen, Fuel Cell, DFMEA, Safety, Laboratory
- report number
- LUTMDN/TMHP-25/5611-SE
- ISSN
- 0282-1990
- language
- English
- id
- 9174211
- date added to LUP
- 2025-01-23 11:27:49
- date last changed
- 2025-01-23 11:27:49
@misc{9174211,
abstract = {{The thesis focuses on the design of a laboratory setup for a 100 kW fuel cell system, intended for heavy-duty vehicle applications. The increasing interest in Proton Exchange Membrane (PEM) fuel cells as a viable alternative for long-haul transport stems from the limitations of battery-electric vehicles, particularly due to the weight and energy density constraints of current battery technologies. Hydrogen, with its significantly higher specific energy compared to lithium-ion batteries, presents a promising solution for electrifying long-range transportation. However, the use of hydrogen in an enclosed space poses greater safety risks than in an open area. Therefore, the primary objective of this project is to develop safe strategies for hydrogen supply, ventilation of exhaust purge gases, and leak detection mechanisms within the closed laboratory environment. The project methodology primarily involves conducting a Design Failure Modes and Effects Analysis (DFMEA) to identify potential safety risks, followed by the design of safety measures. The design process integrates knowledge from regulations, existing industry standards and inhouse knowledge used for building the hydrogen system used in combustion engine test cells at the department of energy sciences, LTH, thereby ensuring the safe operation of the fuel cell system. The outcome of this thesis will provide a robust laboratory infrastructure, enabling future research and development in fuel cell technology for heavy-duty vehicles.}},
author = {{Harikumar, Sidharth}},
issn = {{0282-1990}},
language = {{eng}},
note = {{Student Paper}},
title = {{Design of a Fuel Cell Laboratory}},
year = {{2024}},
}