Tersus, based on the PowerTap™ Gen-2 model coupled with their IP, is proposing to develop an advanced, stationary, and flexible fuel processor (FP) to produce hydrogen onsite for automotive and HD trucks. A new generation of low-pressure steam reformers will need to be produced to address the widest range of specifications with the highest safety standards. The FP will be designed for high efficiency and long life, while maintaining a low capital cost. They will observe Design for Manufacturing and Assembly (DFM&A) principles and will respect emissions standards and while affording scalability. Scalability is a central objective to defray development costs associated with new requirements and applications conceived in the future. Due to economy of scale principles, the challenge to making a low-cost FP increases as its size decreases. The intent is to develop a low-cost FP that produces 1250kg/day hydrogen output to cover the needs of the consumer transportation market. Coupling 4 of these units will create a solution for truck stops that could produce up to 5000kg/day for HD trucks.
The objective of Tersus Power will be to develop a modular steam reformer while maintaining balance between cost, efficiency, durability, manufacturability and environmental standards. A low-pressure steam reformer was designed to address the widest range of applications with the lowest risk. The reformer was designed for long life, low capital cost in accord with DFM&A principles, maintaining high efficiency while respecting strict emissions regulations. The most significant stigma associated with small-scale reformers is durability. Although industrial scale reformers have been in use for decades, they rarely see more than a few thermal cycles per year. In order for a small-scale fuel processor to survive frequent thermal cycles (perhaps daily), the stresses must be reduced to exceptionally low levels and interaction between creep, corrosion and cyclic fatigue must be minimized.
The fuel processor design philosophy incorporated the functional requirements, design of the reforming process, inputs from CFD and FEA modeling and DFM&A principles to influence the mechanical design, a stress & failure mode analysis, material selection, and a life-cycle cost analysis to arrive at the final detailed design.
Modular Fueling Station
Tersus Power sole objective is to design a safe, adaptable, and affordable hydrogen fueling station that allows for rapid development and deployment of hydrogen fueling infrastructure, while minimizing the risk to our investors. Our modular pre-fabricated fueling stations could be produced on a very large scale and available immediately for delivery to our participating sites in order to meet the growing demand for hydrogen fuel. The success of these stations will build increased confidence in the hydrogen vehicle market for both consumers and investors.
The station production equipment will be housed in a modular steel hardened exoskeleton platform similar to a 40 ft shipping container depending on the production requirements for a given site. The platform would contain a fully operational hydrogen production system. Each fueling station will be preassembled and rigorously tested in our own manufacturing facility to insure minimum configuration at time of delivery. The design enhanced side panels that cover the structure will give it a permanent look and feel while providing further stability to the structure as a whole. The panels will be removable to provide access to production equipment for the purposes of maintenance and repair.
The modular fueling station will be placed on the existing site on a prepared concrete pad that could support a more permanent installation. This approach allows for a narrowly focused permitting process which is necessary to connect the modular fueling stations to onsite utilities supporting the production of hydrogen.