The document describes the design of a hydrogen fueling station for a residential building. It will produce hydrogen on-site through electrolysis and compress and dispense it for fuel cell vehicles. The station is designed to service 40 cars per day with compressed hydrogen stored in a secure room meeting safety standards. It utilizes solar and wind energy and includes a heat recovery system. An analysis found the station would offset over 10% of emissions compared to gasoline vehicles.

2. • best mix of educational knowledge and practical
experience
• Fuel Cell Design, Fuel Cell Reliability and Failure
Modes, Accelerated Testing, Conductive Polymer
Blends, Hydrogen Production and Distribution,
Greener Energy System, Life Cycle Analysis

3. • Design a fuelling station for light-duty hydrogen
FCVs for integration into a single residential
building
• Production, compression, potential storage, and
dispensing elements to be included
• Service a minimum daily capacity of 0.8 kg
hydrogen/day/car
• based upon a 35 mile/day commute
• 44 mile/kg fuel economy light-duty fuel cell vehicles
• hydrogen must be compressed to 35 MPa (5000 psig)

4. • High rise condominium building
• Located in Waterloo Research and Technology Park

7. • Hydrogenics HySTAT 15 electrolyzer
• 15 Nm3/hr produced
• 32.4 kg/day
• 10 bar discharge
• built-in water purification
• municipal water input
• produces FCV-pure H2
• 99.999% pure
• Capable of fuelling 40 cars per day according to
design requirements

8. Two-stage
Diaphragm
Compressor
Booster Compressor
Cascade Mass of H2 (Full) Tank Volume
Low Pressure 14 kg 0.60 m3
Medium Pressure 10 kg 0.43 m3
High Pressure 10 kg 0.43 m3

9. • located upon entrance to parking garage for
ease of access
• three-line charging system (priority controls)
• electronic compensation for temperature and
pressure effects
• SAE J2600 compliant nozzles with SAE J2601
compliant dispenser-vehicle communications
• maximum fill time: 5 minutes

11. Key Features:
• blast-proof walls (2 hour fire resistance)
• blast-proof windows with thermoplastic glaze
• holds all major equipment (electrolyzer, primary and
booster compression, storage cascade)
• pressure relief system with inert purging gas
• outside ventilation
• limited access (maintenance staff only)

12. • FMEA revealed significant hazards associated with
human error, deliberate vandalism / terrorism, external
fires, flooding and weather conditions, and potential
valve failures, blockages or leaks along the lines
• Main potential consequences of these hazards include
fire, explosion and suffocation
• Equipment placed in a secure special room designed to
BNQ Hydrogen Installation Code. Dispenser on outdoor
island protected by concrete-filled pipes
• Process control system shuts down equipment if fire,
leak, or elevated temperatures or pressures detected
• Individual system components designed to relevant
codes and standards

13. • Heat recovery for water and
space heating
• Electrolyzer energy consumed
• 683,280 kWh/year
• 290 solar photovoltaic (PV)
panels
• 60,030 kWh/year
• 4 Wind turbines
• 7000+ kWh/year
• 20 Human Powered Bicycles
(fitness room)
• 10,676 kWh/year
Leadership in Environmental
and Energy Design (LEED®)
Gold Certification
Credits include:
• Being close to public transit
• Low Emitting Materials
(paint)
• Light Pollution Reduction
TOTAL OFFSET = 11.3%

14. 0.000
50.000
100.000
150.000
200.000
250.000
300.000
350.000
Gasoline (Low S) 2010 Gasoline (Low S) 2050 CH2 Fuel Cell 2010 CH2 Fuel Cell 2050
CO2Equiv(g/km)
Type of Fuel and Year
Carbon Equivalent Emissions –
Conventional Gasoline vs FCVs
Vehicle Operation
Upstream
Vehicle Material & Assembly

15. • Savings of $404.8/year
• Cost to produce 1 kg of H2 is $3.90
• Refueling stations available in Torrance, California for
the Honda FCX Clarity
• Hydrogenics and ITM Power have built electrolysis units
especially for residential use
• Technologies improving, will be more common in
the future
Vehicle Type Cost ($/year)
Conventional ICE $1532.58
Fuel Cell Vehicle $1127.78

16. Key strategies:
• viral marketing campaign
• local newspaper feature
• bus shelter and exterior
advertising
• branding of UW’s FCV
• info sessions @ UW
• open-door cafe in building
• comprehensive info station
at condominium