It may be more straightforward to add hydrogen fueling stations than previously thought. One of the many challenges faced by a developing hydrogen fueling infrastructure is where to site new stations. Thus, the thought: What if hydrogen fueling could be added to existing gas stations at a more affordable cost?

A recent study by Sandia National Laboratories concludes that a number of existing gas stations in California can safely store and dispense hydrogen, illustrating that a broader network of hydrogen fueling stations may be within reach. Seventy gas stations in California – the state with the largest number of existing hydrogen stations – were examined to determine if any could add hydrogen fueling based on the 2011 NFPA 2 hydrogen technologies code published by NFPA (National Fire Protection Association).

The result? It appears that 14 of the 70 stations explored could readily accept hydrogen fuel, with an additional 17 potentially able to integrate hydrogen with property expansions. The code provides fundamental safeguards for the generation, installation, storage, piping, use, and handling of hydrogen in gaseous or cryogenic liquid form. According to Sandia, a key factor in the codes is the separation required for fueling infrastructure, including fuel dispensers, air intakes and tanks, and storage equipment. The code defines required distances between such components and public streets, parking, on-site convenience stores, and perimeter lines around the site.

The study shows that more hydrogen fueling stations can be built if safety issues are examined within a technical framework that focuses on the real behaviors of hydrogen. Under the previous code, which was developed through an expert opinion-based process rather than the risk-informed process developed by Sandia, virtually no hydrogen fuel cell stations could be sited at existing stations. Also, the previous code was developed for flammable gases in an industrial setting, which carries different risks compared to hydrogen fuel at a fueling station.

Clean Energy Fuels has been hard at work building out a network of natural gas fueling stations along major trucking corridors across the country. The goal is to enable long-haul 18-wheelers to travel coast-to-coast, border-to-border on liquefied natural gas (LNG), a clean-burning and mostly domestic alternative fuel. To supply LNG for these trucks, Clean Energy has completed its initial phase with 70 LNG stations in operation and is moving ahead with another 80 planned for 2013. Many will be co-located at Pilot-Flying J Travel Centers. Pilot-Flying J operates the greatest number of truck stops in the U.S.

Why is this nationwide fueling network important? Truckers could save as much as 25 percent on their fuel bills while cutting CO2 emissions and helping meet the national goal of energy independence. These are three major transportation goals being addressed with a single strategy.

Joining in this effort is GE Oil & Gas, which is supplying its MicroLNG plants to produce LNG from pipeline natural gas. These plug-and-play modular plants can rapidly liquefy natural gas, producing between 50,000 to 250,000 tons-per-year while using a minimum of real estate. This compares to half a million tons, or more, of LNG annually produced by large LNG production plants, usually for international export.

Initially, Clean Energy is purchasing two GE MicroLNG plants that can produce up to 250,000 gallons-per-day, an amount sufficient to fuel about 28,000 heavy-duty trucks. This could displace more than 139,000 metric tons of CO2 emissions per year, equivalent to the annual greenhouse gas emissions from 7,000 trucks running on diesel fuel.

The two GE MicroLNG plants are planned to begin operation in 2015 at locations yet to be determined. As more fleets adopt LNG and demand for this natural gas fuel increases, plants could be expanded to produce up to a million gallons-per-day. Clean Energy plans to use a standardized design for these MicroLNG plants to facilitate building additional plants in the future.

Beyond applications as part of this nationwide fueling vision, MicroLNG plants can also provide small-scale LNG production for remote industrial and residential use. A MicroLNG plant can liquefy natural gas at any point along a gas distribution network. GE’s Micro LNG plants are also simple to install, operate, and maintain, and can be customized to meet a wide range of needs and site requirements.

Engine and truck manufacturers Cummins-Westport, Kenworth, Peterbilt, Navistar, Freightliner, and Caterpillar are all expected to have engines and Class-8 trucks available to use LNG. In 2013, four of the nation’s major truck manufacturers will offer the Cummins Westport 12-liter ISX12 G LNG engine as an option in long-haul Class 8 trucks.

Compared to compressed natural gas used in light-duty vehicles, LNG provides significantly longer driving range without compromising payload, making use of this fuel a very viable option.