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T E C H N I C A L   A R T I C L E

The Hydrogen Highway™
"Something is Being Done!"

Nigel Fitzpatrick
Acquire Innovations Corp.
Vancouver, BC, Canada



Over the next 20 years, U.S. daily consumption of oil will grow by more than 6 million barrels. So says an Energy Report, signed by Dick Cheney, posted on the White House website (www.whitehouse.gov/energy). In the words of Edward VIII, when touring the heavily polluted and poverty-stricken mining valleys of South Wales just before his unhappy departure from the throne, “Something needs to be done!”

It is always intriguing to find that BC gives Canada a leadership role in alternative fuel technologies despite there being 79 countries on the planet where gasoline is sold at a higher price (www.nationmaster.com/graph-T/ene_ gas_pri&int=-1). Perhaps we do so well simply because of the lower fuel prices in the United States or maybe the lack of a serious winter in British Columbia allows us to helpfully worry about the rest of Canada and most of the U.S. freezing.

In BC we are now developing the Hydrogen Highway™. It will guide vehicles from the longest undefended border in the world through Vancouver to Whistler, BC, before the 2010 Winter Olympics. According to Ron Britton (rbritton@fuelcellscanada.ca), the CEO of Fuel Cells Canada, the trademarked name is in the process of being assigned to FCC who will provide the organizational infrastructure. It was originally thoughtfully registered by Methanex (www.methanex.com), BC Hydro (www. bchydro.com), and the National Research Council of Canada (www.nrc.ca). In Norway, there is a claim to be developing such a highway (www.h2cars.biz/artman/publish/article_343.shtml), but BC’s Hydrogen Highway™ is the one with the trademark. There is cross-border discussion that the term will be offered to the highway reaching north from California. This ™ is intended to encourage sharing, not exclusion.

Ron Britton recently briefed me on the concept when he described seven nodes, i.e., fueling sites in British Columbia. These nodes will not only make it possible for hydrogen-powered vehicles to drive from the Washington State border to Whistler, but will also provide hydrogen and probably hydrogen natural gas blends that can be delivered to vehicles, stationary power generators and small utilities.

The Hydrogen Highway™ Program, which is still in an early stage, is designed to ensure that a number of practical approaches to hydrogen fueling are taken beyond the prototype stage into field use. There will be “nodes” where the hydrogen is made from a number of different sources, including natural gas, electricity, methanol or bio-methanol. Mark Grist of Methanex (mgrist@methanex.com) says that the Whistler station may produce hydrogen from methanol since its reformation is relatively simple and, as yet, there is no natural gas in Whistler.

One fueling station on the Hydrogen Highway™ is already operational. The world’s first 700bar (10,000psig) station is at the Powertech Laboratory (www.power tech.bc.ca) of BC Hydro in Surrey. Renowned for its engineering work on the development of both natural gas and hydrogen cylinders, Powertech is working with Toyota, Nissan, Ford, DaimlerChrysler, Hyundai and PSA Peugeot to develop the world’s first on-board 700bar (10,000psig) gaseous hydrogen storage and fueling system for vehicles. Canadian suppliers, such as IMW Compressors (www.imw.bc.ca) and cylinder supplier Dynetek (www.dynetek.com), are participating in the program.

In natural gas vehicle parlance, the Powertech station is a “mother” facility. Hydrogen produced there by electrolysis can be compressed and transported elsewhere for use without a compressor. The station has been used already to directly fuel a Ford Fuel Cell Focus and is also used routinely to provide a blend of hydrogen and natural gas for engine-equipped trucks.

In effect, according to David Shepherd (dshepherd@fuelcellscanada.ca) of Fuel Cells Canada there is already a “daughter” facility with refueling capability at the National Research Council of Canada facility on the UBC campus. There is also electrolysis on site as well as a new fluidized bed technology from MRT (www.mem branereactor.com) to convert natural gas efficiently to hydrogen. Simply adding a compressor and dispenser would make the site a full-fledged “mother” station.

A “node” is planned in Victoria to support projects at the University of Victoria and also hydrogen vehicles that, necessarily, have to visit the Province’s capital, which is still remotely located, just as it was before a railway crossed the continent. Geoff Wood of Profile Composites (GMWood@aol.com) tells me that he would like to link a lightweight hydrogen hybrid project to this fueling source.

Another exciting, and more central, “node” is planned in North Vancouver that could use byproduct hydrogen from an electrochemical plant that would otherwise be vented into the atmosphere; indeed a fraction of byproduct hydrogen that does not react with oxygen continues off into space and is lost from the planet altogether. Chris Sacré of Sacré-Davey (csacre@sacre-davey.com) described the plan.

In North Vancouver 5,000 tons per year of hydrogen are presently lost. Many other plants that vent hydrogen dot not only Canada but also the entire planet, and applications and demand for some of their products are climbing. For example, sodium chlorate is used more and more for water purification. If we don’t use it, we lose it. The route provides a good full cycle source of hydrogen. You can also find that hydrogen is being recovered already at a chlorate plant in Quebec in a project sponsored by Natural Resources Canada

http://oee.nrcan.gc.ca

Fifty one million tons of chlorine and 2.8 million tons of sodium chlorate were produced around the world in 2002. The combined hydrogen byproduct from just these two products works out to be 1,607,000 annual tons of hydrogen, which is equivalent to 32.7 million barrels of oil per year or up to 44.4 million barrels of oil with the advantage that a fuel cell hybrid has over a diesel hybrid. This hydrogen exists now and simply needs to be, yes, mined, a word we do not normally associate with hydrogen!

The quantity of byproduct hydrogen mentioned above is small in the vast ocean of needs defined by Dick Cheney’s team, but it would provide an excellent resource for centrally refueled fleets in locations where these chemical plants exist – or will exist. The demand for sodium chlorate is growing at the rate of 6% per year, and it is readily shipped to market. The raw material for this product is brine, or seawater

With the Hydrogen Highway™ in mind, BC visionaries like Ron Britton and Chris Sacré will tap into an existing plant in BC that exudes hydrogen. In the first half of the 20th century like-minded people were locating aluminum plants in remote locations. Is there a connection?

Perhaps there is. As the 21st century begins, all around the world, aluminum plants are being replaced with modern, more efficient technology that employs fewer people. Suddenly we have remote locations where excess electricity coexists with homes, schools and people with cars. In some cases, a city is too far from the rest of the world to be accessible by anything but a plane. Cars, trucks and buses here may not need to travel long distances. One wonders whether these homes, schools and vehicles could provide the seeds for a hydrogen economy.

The electricity-using sodium chlorate industry is growing and more hydrogen is being released. Of course, we could simply ship in the hydrogen, but what if we shipped out sodium chlorate and used the hydrogen locally? Could any electrically endowed coastal city become the center of a hydrogen industry? BC has several candidate coastal sites; indeed, Nanaimo already has waste hydrogen from a chlorate plant.

Such a move would, of course, provide centers of development and distributed power generation that will need software to manage it such as that developed by Bill Havens at Actenum Corp. (www.actenum.com). It would develop jobs and skills in communities that are presently puzzling what other business can be developed.

All agree that the key to success will be to keep the nodes, or fuel stations, of the Hydrogen Highway™ busy. There is a flurry of activity to identify a range of projects that will use hydrogen, both pure and blended with natural gas. In Surrey there are already Hythane trucks. Westport Innovations (www.westport.com) will be proposing further Hythane buses; there is also talk of hydrogen at hybrid vehicle developer Azure Dynamics (www.azure dynamics.com). Others are talking of stationary fuel cells, PEMFC, DMFC and SOFC, for which proposals are expected relating to power and heat for the athletes’ villages for 2010, remote power needs, and small vehicles.

At the Whistler node especially, where the planned source of the hydrogen may be methanol, it is expected we can anticipate that there will be projects using DMFC technology in which we saw Methanex involved at EVS20.

Above all, knowledge will be communicated up and down the Hydrogen Highway™ from California to Whistler. This will avoid the experience suffered by the driver of a natural gas car from BC that I met at EVS12 in December 1994. The vehicle was driven 1500 miles to the EVS12 meeting in Anaheim from Vancouver, BC. It made the trip only because it was a bi-fuel car and could fill up with gasoline. There was no shortage of natural gas stations on the route; it was simply that each jurisdiction required a different mechanical connector to refuel the vehicle. By communicating and sharing information we can avoid problems like this and succeed in our visions. This is what Ron Britton and the Hydrogen Highway™ Team are planning to do. As the “highway” is built more than vehicles may come. The support of work to mine the hydrogen produced as a byproduct may well prevent some coastal communities from declining.

Of this 21st century hydrogen mining, Edward VIII may well have said, “Something is being done!”

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