Safety
CFD Computations of Liquid Hydrogen Releases
Sep 2011
Publication
Hydrogen is widely recognized as an attractive energy carrier due to its low-level air pollution and its high mass-related energy density. However its wide flammability range and high burning velocity present a potentially significant hazard. A significant fraction of hydrogen is stored and transported as a cryogenic liquid (liquid hydrogen or LH2) as it requires much less volume compared to gaseous hydrogen. In order to exist as a liquid H2 must be cooled to a very low temperature 20.28 K. LH2 is a common liquid fuel for rocket applications. It can also be used as the fuel storage in an internal combustion engine or fuel cell for transport applications. Models for handling liquid releases both two-phase flashing jets and pool spills have been developed in the CFD-model FLACS. The very low normal boiling point of hydrogen (20 K) leads to particular challenges as this is significantly lower than the boiling points of oxygen (90 K) and nitrogen (77 K). Therefore a release of LH2 in the atmosphere may induce partial condensation or even freezing of the oxygen and nitrogen present in the air. A pool model within the CFD software FLACS is used to compute the spreading and vaporization of the liquid hydrogen depositing on the ground where the partial condensation or freezing of the oxygen and nitrogen is also taken into account. In our computations of two-phase jets the dispersed and continuous phases are assumed to be in thermodynamic and kinematic equilibrium. Simulations with the new models are compared against selected experiments performed at the Health and Safety Laboratory (HSL).
CFD Modeling for Helium Releases in a Private Garage Without Forced Ventilation.
Sep 2005
Publication
In the course towards a safe future hydrogen based society one of the tasks to be considered is the investigation of the conditions under which the use or storage of hydrogen systems inside buildings becomes too dangerous to be accepted. One of the relevant scenarios which is expected to have a relatively high risk is a slow (and long lasting) hydrogen release from a vehicle stored in a closed private garage without any forced ventilation i.e. only with natural ventilation. This scenario has been earlier investigated experimentally (by M. Swain) using He (helium) to simulate the hydrogen behavior. In the present work the CFD code ADREA-HF is used to simulate three of the abovementioned experiments using the standard k- turbulence model. For each case modeled the predicted concentration (by vol.) time series are compared against the experimental at the given sensor locations. In addition the structure of the flow is investigated by presenting the helium concentration field.
Dynamic Crush Test on Hydrogen Pressurized Cylinder
Sep 2005
Publication
It is necessary to investigate cylinder crush behavior for improvement of fuel cell vehicle crash safety. However there have been few crushing behaviour investigations of high pressurized cylinders subjected to external force. We conducted a compression test of pressurized cylinders impacted by external force. We also investigated the cylinder strength and crushing behaviour of the cylinder. The following results were obtained.
- The crush force of high pressurized cylinders is different from the direction of external force. The lateral crush force of high pressurized cylinders is larger than the external axial crush force.
- Tensile stress occurs in the boundary area between the cylinder dome and central portion when the pressurized cylinder is subjected to axial compression force and the cylinder is destroyed.
- However the high pressurized cylinders tested had a high crush force which exceeded the assumed range of vehicle crash test procedures
Rayleigh-Taylor Instability: Modelling and Effect on Coherent Deflagrations
Sep 2013
Publication
The modelling of Rayleigh–Taylor instability during premixed combustion scenarios is presented. Experimental data obtained from experiments undertaken by FM Global using their large-scale vented deflagration chamber was used to develop the modelling approach. Rayleigh–Taylor instability is introduced as an additional time-dependent combustion enhancing mechanism. It is demonstrated that prior to the addition of this mechanism the LES deflagration model under-predicted the experimental pressure transients. It is confirmed that the instability plays a significant role throughout the coherent deflagration process. The addition of the mechanism led to the model more closely replicating the pressure peak associated with the external deflagration.
Application of Reactive Discrete Equation Method to the ENACCEF Test 13h
Sep 2011
Publication
The Reactive Discrete Equation Method (RDEM) was recently introduced in [12] adapted to combustion modelling in [3] and implemented in the TONUS code [4]. The method has two major features: the combustion constant having velocity dimension is the fundamental flame speed and the combustion wave now is an integral part of the Reactive Riemann Problem. In the present report the RDEM method is applied to the simulation of the combustion Test 13H performed in the ENACCEF facility. Two types of computations have been considered: one with a constant fundamental flame speed the other with time dependent fundamental flame speed. It is shown that by using the latter technique we can reproduce the experimental visible flame velocity. The ratio between the fundamental flame speed and the laminar flame speed takes however very large values compared to the experimental data based on the tests performed in spherical bombs or cruciform burner.
Experimental Study of Vented Hydrogen Deflagration with Ignition Inside and Outside the Vented Volume
Sep 2013
Publication
Experiments were carried out inside a 25 m3 vented combustion test facility (CVE) with a fixed vent area sealed by a plastic sheet vent. Inside the CVE a 0.64 m3 open vent box called RED-CVE was placed. The vent of the RED-CVE was left open and three different vent area were tested. Two different mixing fans one for each compartment were used to establish homogeneous H2 concentrations. This study examined H2 concentrations in the range between 8.5% vol. to 12.5% vol. and three different ignition locations (1) far vent ignition (2) inside the RED-CVE box ignition and (3) near vent ignition (the vent refers to the CVE vent). Peak overpressures generated inside the test facility and the smaller compartment were measured. The results indicate that the near vent ignition generates negligible peak overpressures inside the test facility as compared to those originated by far vent ignition and ignition inside the RED-CVE box. The experiments with far vent ignition showed a pressure increase with increasing hydrogen concentration which reached a peak value at 11% vol. concentration and then decreased showing a non-monotonic behaviour. The overpressure measured inside the RED-CVE was higher when the ignition was outside the box whereas the flame entered the box through the small vent.
Experimental Investigation of Hydrogen Jet Fire Mitigation by Barrier Walls
Sep 2009
Publication
Hydrogen jet flames resulting from ignition of unintended releases can be extensive in length and pose significant radiation and impingement hazards. One possible mitigation strategy to reduce exposure to jet flames is to incorporate barriers around hydrogen storage and delivery equipment. While reducing the extent of unacceptable consequences the walls may introduce other hazards if not properly configured. This paper describes experiments carried out to characterize the effectiveness of different barrier wall configurations at reducing the hazards created by jet fires. The hazards that are evaluated are the generation of overpressure during ignition the thermal radiation produced by the jet flame and the effectiveness of the wall at deflecting the flame.<br/>The tests were conducted against a vertical wall (1-wall configuration) and two “3-wall” configurations that consisted of the same vertical wall with two side walls of the same dimensions angled at 135° and 90°. The hydrogen jet impinged on the center of the central wall in all cases. In terms of reducing the radiation heat flux behind the wall the 1-wall configuration performed best followed by the 3-wall 135° configuration and the 3-wall 90°. The reduced shielding efficiency of the three-wall configurations was probably due to the additional confinement created by the side walls that limited the escape of hot gases to the sides of the wall and forced the hot gases to travel over the top of the wall.<br/>The 3-wall barrier with 135° side walls exhibited the best overall performance. Overpressures produced on the release side of the wall were similar to those produced in the 1-wall configuration. The attenuation of overpressure and impulse behind the wall was comparable to that of the three-wall configuration with 90° side walls. The 3-wall 135° configuration’s ability to shield the back side of the wall from the heat flux emitted from the jet flame was comparable to the 1-wall and better than the 3-wall 90° configuration. The ratio of peak overpressure (from in front of the wall and from behind the wall) showed that the 3-wall 135° configuration and the 3-wall 90° configuration had a similar effectiveness. In terms of the pressure mitigation the 3-wall configurations performed significantly better than the 1-wall configuration
Deflagration Safety Study of Mixtures of Hydrogen and Natural Gas in a Semi-open Space
Sep 2007
Publication
In the transition to a hydrogen economy it is likely that hydrogen will be used or stored in close proximity to other flammable fuels and gases. Accidents can occur that result in the release of two or more fuels such as hydrogen and natural gas that can mix and form a hazard. A series of five medium-scale semi-open-space deflagration experiments have been conducted with hydrogen natural gas and air mixtures. The natural gas consisted of 90% methane 6% ethane 3% propane and 1% butane by volume. Mixtures of hydrogen and natural gas were created with the hydrogen mole fraction in the fuel varying from 1.000 to 0.897 and the natural gas mole fraction varying from 0.000 to 0.103. The hydrogen and natural gas mixture was then released inside a 5.27-m³ thin plastic tent. The stoichiometric fuel-air mixtures were ignited with a 40-J spark located at the bottom center of the tent. Overpressure and impulse data were collected using pressure transducers located within the mixture volume and in the free field. Flame front time-of-arrival was measured using fast response thermocouples and infrared video. Flame speeds relative to a fixed observer were measured between 36.2 m/s and 19.7 m/s. Average peak overpressures were measured between 2.0 kPa and 0.3 kPa. The addition of natural gas inhibited the combustion when the hydrogen mole fraction was less than or equal to 0.949. For these mixtures there was a significant decrease in overpressures. When the hydrogen mole fraction in the fuel was between 0.999 and 0.990 the overpressures were slightly higher than for the case of hydrogen alone. This could be due to experimental scatter or there may be a slight enhancement of the combustion when a very small amount of natural gas was present. From a safety standpoint variation in overpressure was small and should have little effect on safety considerations.
A Homogeneous Non-equilibrium Two-phase Critical Flow Model
Sep 2011
Publication
A non-equilibrium two-phase single-component critical (choked) flow model for cryogenic fluids is developed from first principle thermodynamics. Modern equations-of-state (EOS) based upon the Helmholtz free energy concepts are incorporated into the methodology. Extensive validation of the model is provided with the NASA cryogenic data tabulated for hydrogen methane nitrogen and oxygen critical flow experiments performed with four different nozzles. The model is used to develop a hydrogen critical flow map for stagnation states in the liquid and supercritical regions.
Simulations of Hydrogen Releases from a Storage Tanks- Dispersion and Consequences of Ignition
Sep 2005
Publication
We present results from hydrogen dispersion simulations from a pressurized reservoir at constant flow rate in the presence and absence of a wall. The dispersion simulations are performed using a commercial finite volume solver. Validation of the approach is discussed. Constant concentration envelopes corresponding to the 2% 4% and 15% hydrogen concentration in air are calculated for a subcritical vertical jet and for an equivalent subcritical horizontal jet from a high pressure reservoir. The consequences of ignition and the resulting overpressure are calculated for subcritical horizontal and vertical hydrogen jets and in the latter case compared to available experimental data.
The New Facility for Hydrogen and Fuel Cell Vehicle Safety Evaluation
Sep 2005
Publication
For the evaluation of hydrogen and fuel cell vehicle safety a new comprehensive facility was constructed in our institute. The new facility includes an explosion resistant indoor vehicle fire test building and high pressure hydrogen tank safety evaluation equipment. The indoor vehicle fire test building has sufficient strength to withstand even an explosion of a high pressure hydrogen tank of 260 liter capacity and 70 MPa pressure. It also has enough space to observe vehicle fire flames of not only hydrogen but also other conventional fuels such as gasoline or compressed natural gas. The inside dimensions of the building are a 16 meter height and 18 meter diameter. The walls are made of 1.2 meter thick reinforced concrete covered at the insides with steel plate. This paper shows examples of hydrogen vehicle fires compared with other fuel fires and hydrogen high pressure tank fire tests utilizing several kinds of fire sources. Another facility for evaluation of high pressure hydrogen tank safety includes a 110 MPa hydrogen compressor with a capacity of 200 Nm3/h a 300 MPa hydraulic compressor for burst tests of 70 MPa and higher pressure tanks and so on. This facility will be used for not only the safety evaluation of hydrogen and fuel cell vehicles but also the establishment of domestic/international regulations codes and standards.
Integral Models for High Pressure Hydrogen - Methane Releases
Sep 2009
Publication
The development of hydrogen as energy carrier is promoted by the increasing in energy demand depletion of fossil resources and the global warming. However this issue relies primarily on the safety aspect which requires the knowledge in the case of gas release of the quantities such as the flammable cloud size release path and the location of the lower flammability limit of the mixture. The integral models for predicting the atmospheric dispersion were extensively used in previous works for low pressure releases such as pollutant and flammable gas transport. In the present investigation this approach is extended to the high pressure gas releases. The model is developed in the non-Boussinesq approximation and is based on Gaussian profiles for buoyant variable density jet or plume in stratified atmosphere with a crossflow. Validations have been performed on a broad range of hydrogen methane and air dispersion cases including vertical or horizontal jets or plumes into a quiescent atmosphere or with crosswind.
Explosion Characteristics of Hydrogen-air and Hydrogen-Oxygen Mixtures at Elevated Pressures
Sep 2005
Publication
An essential problem for the operation of high pressure water electrolyzers and fuel cells is the permissible contamination of hydrogen and oxygen. This contamination can create malfunction and in the worst case explosions in the apparatus and gas cylinders. In order to avoid dangerous conditions the exact knowledge of the explosion characteristics of hydrogen/air and hydrogen/oxygen mixtures is necessary. The common databases e.g. the CHEMSAFE® database published by DECHEMA BAM and PTB contains even a large number of evaluated safety related properties among other things explosion limits which however are mainly measured according to standard procedures under atmospheric conditions.<br/>Within the framework of the European research project “SAFEKINEX” and other research projects the explosion limits explosion pressures and rates of pressure rise (KG values) of H2/air and H2/O2 mixtures were measured at elevated conditions of initial pressures and temperatures by the Federal Institute of Materials Research and Testing (BAM). Empirical equations of the temperature influence could be deduced from the experimental values. An anomaly was found at the pressure influence on the upper explosion limits of H2/O2 and H2/air mixtures in the range of 20 bars. In addition explosion pressures and also rates of pressure rises have been measured for different hydrogen concentrations inside the explosion range. Such data are important for constructive explosion protection measures. Furthermore the mainly used standards for the determination of explosion limits have been compared. Therefore it was interesting to have a look at the systematic differences between the new EN 1839 tube and bomb method ASTM E 681-01 and German DIN 51649-1.
Safety of Hydrogen-fueled Motor Vehicles with IC Engines.
Sep 2005
Publication
Clarification of questions of safety represents a decisive contribution to the successful introduction of vehicles fuelled by hydrogen. At the moment the safety of hydrogen is being discussed and investigated by various bodies. The primary focus is on fuel-cell vehicles with hydrogen stored in gaseous form. This paper looks at the safety of hydrogen-fuelled vehicles with an internal combustion engine and liquefied hydrogen storage. The safety concept of BMW’s hydrogen vehicles is described and the specific aspects of the propulsion and storage concepts discussed. The main discussion emphasis is on the utilization of boil-off parking of the vehicles in an enclosed space and their crash behaviour. Theoretical safety observations are complemented by the latest experimental and test results. Finally reference is made to the topic-areas in the field of hydrogen safety in which cooperative research work could make a valuable contribution to the future of the hydrogen-powered vehicle.
Flame Characteristics of High-Pressure Hydrogen Gas Jet
Sep 2005
Publication
It is expected that hydrogen will serve as a nonpolluting carrier of energy for the next generation of vehicles and guidelines for its safe use are required. Hydrogen-gas service stations for supplying fuel cell vehicles will have to handle high-pressure hydrogen gas but safety regulations for such installations have not received much investigation. In this study we experimentally investigated the flame characteristics of a rapid leakage of high-pressure hydrogen gas. A hydrogen jet diffusion flame was injected horizontally from convergent nozzles of various diameters between 0.1 and 4 mm at reservoir over pressures of between 0.01 and 40 MPa. The sizes of the flame were measured and experimental equations were obtained for the length and the width of the flame. Flame sizes depend not only on the nozzle diameter but also on the spouting pressure. Blow-off limits exists and are determined by the nozzle diameter and the spouting pressure. Furthermore the radiation from a hydrogen flame can be predicted from the flow rate of the gas and the distance from the flame.
Role of Chemical Kinetics on the Detonation Properties of Hydrogen, Natural Gas & Air Mixtures
Sep 2005
Publication
The first part of the present work is to validate a detailed kinetic mechanism for the oxidation of hydrogen – methane – air mixtures in a detonation waves. A series of experiments on auto-ignition delay times have been performed by shock tube technique coupled with emission spectrometry for H2 / CH4 / O2 mixtures highly diluted in argon. The CH4/H2 ratio was varied from 0 to 4 and the equivalence ratio from 0.4 up to 1. The temperature range was from 1250 K to 2000 K and the pressure behind reflected shock waves was between 0.15 and 1.6 MPa. A correlation was proposed between temperature (K) concentration of chemical species (mol m-3) and ignition delay times. The experimental auto-ignition delay times were compared to the modelled ones using four different mechanisms from the literature: GRI [22] Marinov et al. [23] Hughes et al. [24] Konnov [25]. A large discrepancy was generally found between the different models. The Konnov’s model that predicted auto-ignition delay times close to the measured ones has been selected to calculate the ignition delay time in the detonation waves. The second part of the study concerned the experimental determination of the detonation properties namely the detonation velocity and the cell size. The effect of the initial composition hydrogen to methane ratio and the amount of oxygen in the mixture as well as the initial pressure on the detonation velocity and on the cell size were investigated. The ratio of methane / (methane + hydrogen) varied between 0 and 0.6 for 2 different equivalence ratio (0.75 and 1) while the initial pressure was fixed to 10 kPa. A correlation was established between the characteristic cell size and the ignition delay time behind the leading shock of the detonation. It was clearly showed that methane has an important inhibitor effect on the detonation of these combustible mixtures.
Measuring and Modelling Unsteady Radiation of Hydrogen Combustion
Sep 2005
Publication
Burning hydrogen emits thermal radiation in UV NIR and IR spectral range. Especially in the case of large cloud explosion the risk of heat radiation is commonly underestimated due to the non-visible flame of hydrogen-air combustion. In the case of a real explosion accident organic substances or inert dust might be entrained from outer sources to produce soot or heated solids to substantially increase the heat release by continuum radiation. To investigate the corresponding combustion phenomena different hydrogen-air mixtures were ignited in a closed vessel and the combustion was observed with fast scanning spectrometers using a sampling rate up to 1000 spectra/s. In some experiments to take into account the influence of organic co-combustion a spray of a liquid glycol-ester and milk powder was added to the mixture. The spectra evaluation uses the BAM code of ICT to model bands of reaction products and thus to get the temperatures. The code calculates NIR/IR-spectra (1 - 10 μm) of non-homogenous gas mixtures of H2O CO2 CO NO and HCl taking into consideration also emission of soot particles. It is based on a single line group model and makes also use of tabulated data of H2O and CO2 and a Least Squares Fit of calculated spectra to experimental ones enables the estimation of flame temperatures. During hydrogen combustion OH emits an intense spectrum at 306 nm. This intermediary radical allows monitoring the reaction progress. Intense water band systems between 1.2 and 3 μm emit remarkable amounts of heat radiation according to a measured flame temperature of 2000 K. At this temperature broad optically-thick water bands between 4.5 μm and 10 μm contribute only scarcely to the total heat output. In case of co-combustion of organic materials additional emission bands of CO and CO2 as well as a continuum radiation of soot and other particles occur and particularly increase the total thermal output drastically.
Analysis Methodology for Hydrogen Behaviour in Accident Scenarios
Sep 2005
Publication
Hydrogen is not more dangerous than current fossil energy carriers but it behaves differently. Therefore hydrogen specific analyses and countermeasures will be needed to support the development of safe hydrogen technologies. A systematic step-by-step procedure for the mechanistic analysis of hydrogen behaviour and mitigation in accidents is presented. The procedure can be subdivided into four main parts:<br/>1) 3D modelling of the H2-air mixture generation<br/>2) hazard evaluation for this mixture based on specifically developed criteria for flammability flame acceleration and detonation on-set<br/>3) numerical simulation of the appropriate combustion regime using verified 3D-CFD codes and<br/>4) consequence analysis based on the calculated pressure and temperature loads.
PRD Hydrogen Release and Dispersion, a Comparison of CFD Results Obtained from Using Ideal and Real Gas Law Properties.
Sep 2005
Publication
In this paper CFD techniques were applied to the simulations of hydrogen release from a 400-bar tank to ambient through a Pressure Relieve Device (PRD) 6 mm (¼”) opening. The numerical simulations using the TOPAZ software developed by Sandia National Laboratory addressed the changes of pressure density and flow rate variations at the leak orifice during release while the PHOENICS software package predicted extents of various hydrogen concentration envelopes as well as the velocities of gas mixture for the dispersion in the domain. The Abel-Noble equation of state (AN-EOS) was incorporated into the CFD model implemented through the TOPAZ and PHOENICS software to accurately predict the real gas properties for hydrogen release and dispersion under high pressures. The numerical results were compared with those obtained from using the ideal gas law and it was found that the ideal gas law overestimates the hydrogen mass release rates by up to 35% during the first 25 seconds of release. Based on the findings the authors recommend that a real gas equation of state be used for CFD predictions of high-pressure PRD releases.
Hydrogen Fuelling Station, CEP-Berlin – Safety Risk Assessment and Authority Approval Experience and Lessons Learned
Sep 2005
Publication
The CEP (Clean Energy Partnership) – Berlin is one of the most diversified hydrogen demonstration projects at present. The first hydrogen fuelling station serving 16 cars is fully integrated in an ordinary highly frequented Aral service station centrally located at Messedamm in Berlin. Hydro has supplied and is the owner of the electrolyser with ancillary systems. This unit produces gaseous hydrogen at 12 bar with use of renewable energy presently serving 13 of the cars involved. The CEP project is planned to run for a period of five years and is supported by the German Federal Government and is part of the German sustainability strategy. During the planning and design phase there have been done several safety related assessments and analyses:
- Hydro has carried out a HAZOP (HAZard and OPerability) analysis of the electrolyser and ancillary systems delivered by Hydro Electrolysers.
- Hydro arranged with support from the partners a HAZOP analysis of the interface between the electrolyser and the compressor an interface with two different suppliers on each side.
- A QRA (Quantitative Risk Assessment) of the entire fuelling station has been carried out.
- Hydro has carried out a quantitative explosion risk analysis of the electrolyser container supplied by Hydro Electrolysers.
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