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: SPASUPATHI@UWC.AC.ZA

WEBSITE: WWW.HYSASYSTEMS.COM