Typical high pressure cylinders must be re-certified every 5 years. There are specific carbon fiber reinforced cylinders that can fall under DOT regulation (SP-16320) which allows a longer span between re-certification.

The typical re-certification procedure requires a physical inspection, inside and out, and a "hydro" pressure test. They fill the tank completely with water and raise the pressure to twice (or 3/2, or 5/3 depending on the design) the rated pressure of the cylinder. (The water doesn't compress and doesn't store much energy when you raise the pressure, so a burst tank makes a dull "thud" instead of a catastrophic bang.)

I suspect the super-ultra-high pressure carbon fiber tanks will be damaged by the over-pressure of the re-certification test, so they probably can't be hydro tested and therefore must be discarded. :-( This is just a guess, however. Perhaps such an extremely high pressure test is prohibitively expensive?

This replacement cost is another "nail in the coffin" of H2 fuel cell vehicles. The cost of a battery replacement is less than the cost of _mandatory_ H2 cylinder replacement. Surprise surprise, another hidden cost of fuel cell vehicle ownership.

Bill D.

On 9/10/2021 5:52 AM, Peter Eckhoff via EV wrote:
Hello Dave,

You raise some interesting questions.  Out of curiosity, I did a
search on Mirai Hydrogen Tank Replacement Cost and came up with a
couple of things:

1)  In this link:
https://insideevs.com/news/326312/2016-toyota-mirai-do-not-refuel-after-2029/

There is a picture from a 2016 article on the Mirai.  In the picture
is a back of the door plate that reads:

Do Not Refuel After:
2029/11

The interesting thing is that it is time based and not based on the
number of refuelings.  I would think that bringing a tank repeatedly
from around a couple of PSI to 5 tons per square inch would stress the
composition and create microcracks and stresses.  But who keeps track
of how many times a vehicle is refueled (or recharged)?

14 years times 15K miles per year is roughly 200K miles.  At a 400
mile range, that's 500 refuelings.  Most of the car reviewers were
finding lower ranges.

If you can't refuel after 14 years of driving this car, then the tanks
need to be replaced????

2.)  For replacement cost ( "Fits Mirai 2021-2021"), I found this ad at:

https://parts.lagrangetoyota.com/a/Toyota__Mirai/97938565__9232000/FUEL-TANK--TUBE/28B420-7701.html#77A30
The number 1 & 2 tanks are each listed at a discounted: $9,313.87.
The number 3 tank is listed at a discounted : $5.665.95

So basically, it would cost $24K at a discounted cost ($30K retail) in
parts to replace those 3 hydrogen tanks.
As a comparison, a Model 3's pack replacement cost is $16K just for the pack:
https://www.thedrive.com/tech/38915/it-costs-nearly-16000-to-replace-a-tesla-model-3-battery-pack
with the life of a pack between 300K and 500K miles.

3.)  With regard to garaging, I was reading a while back that the
hydrogen is so light that it would float and disperse readily
generating the idea a HFCEV could be garaged.  If I find the article I
will post it but the comments you found in a passage about getting it
out and into a well-ventilated space makes me want to find an
authoritative source.  It may be the difference between a slow leak
and something faster.

After 4 to 5 hours on the road, letting an EV recharge while we visit
the restrooms and order a meal takes away from the speed of refueling
a HFCEV.

Peter


On Thu, Sep 9, 2021 at 10:42 AM EVDL Administrator via EV
<[email protected]> wrote:
Thanks Bill.  That's the information I was looking for.

I was curious about whether this was mentioned in the owner manuals of FCVs.
so out of curiosity I downloaded the Mirai manual from the web

https://www.startmycar.com/toyota/mirai/info/manuals/2021

It's 560 pages!  I thought at first that it must be multi-lingual, but nope,
that's all English text.  I confess, I didn't read it all, just skimmed
interesting topics.

First of all, I was specifically looking for information or advice about
ventilating the garage where the owner is going to park the Mirai.  I didn't
find any.  The only mention of "vent" in the index refers to the seat
ventilators.  "Garage" is about Homelink programming.  "Parking" guides us
to parking assist, parking brake, parking lights, and "parking support
brake," which is a low speed collision avoidance system.

The manual has some information about the car's safety systems.  Apparently
it has a hydrogen leakage detector that posts a warning on the info screen.

The car has 3 bulky cylindrical H2 tanks.  The vehicle schematic diagram
showing them made me think of EV conversion, when you have to figure out
where to fit in a dozen or two lead batteries, with  little choice about
their shape.

One H2 tank is in the center between the seats, where a driveshaft would be
in an FE/RD car.  (I thought we were done with that waste of interior
space.)  One appears to be transversely mounted under the seats, and the
third behind the rear axle (shades of the Pinto's gas tank).  They're all
claimed to be physically outside the passenger cabin, so presumably they're
hung underneath.

I don't see dimensions, but they look like they might indeed cover less
total square area than a typical EV battery.  However, they may be taller
than some/most EV lithium batteries.

There's a traction battery, too.  It's smaller than a typical EVs but
appears to be mounted over the rear axle, behind the rear seat.  Depending
on its mass relative to the H2 tanks, that might raise questions about the
car's center of gravity.

In a collision the hydrogen tank valves supposedly shut off.  Given the
location of the transverse tanks, though, I have to wonder how well they'd
hold together in a high speed side T-bone by a 3-ton jacked-up pickup.

The hydrogn tanks have an EXPIRATION DATE!   It's posted on the inside of
the fuel door, and "Vehicles with expired hydrogen tanks must not be driven
or refueled until the hydrogen tanks are replaced."  I wonder what that
costs.

The manual has 113 pages about using the "driving support system," but only
2-1/2 pages of fuel cell and hydrogen warnings.  In that section we find
such gems as:

"If you notice gas leaking or any other malfunction, immediately stop the
vehicle in a safe and well-ventilated place, exit the vehicle, and stay far
away from it."  (Interesting that that use of the word "ventilated" wasn't
in the index.)

"In case of a vehicle fire, the hydrogen gas in the tanks is released angled
downward on the right side and rear of the vehicle, in order to reduce
damage to the hydrogen tanks.  Stay away from the vehicle and do not stand
on either the right side or the rear of the vehicle."  (Maybe it's just my
ignorance, but that doesn't sound good at all.)

"If your vehicle needs to be towed, do so with the rear wheels lifted.  If
the wheels are touching the ground, the motor may continue to generate
electricity.  This may cause a fire."

"If the traction battery is not properly collected [by a dealer], the
following may occur, resulting in death or serious injury: The traction
battery may be illegally disposed [of] or dumped, and it is hazardous to the
environment."

"Do not carry large amounts of water such as water cooler bottles in the
vehicle.  If water spills onto the traction battery, the battery may be
damaged."

Also, "Never drink the water coming out of the tailpipe." :-)

Elsewhere in the manual: "When starting the fuel cell system during cold
weather, 'FCV System Due to Freezing Stop in a Safe Place See Owner Manual'
may be displayed in the multifunction display.  The fuel cell system is
frozen and cannot be started.  See your Toyota dealer."

All quite interesting.  But, again, not a word about ventilating your garage
when you park a Mirai there.

David Roden, EVDL moderator & general lackey

To reach me, don't reply to this message; I won't get it.  Use my
offlist address here : http://evdl.org/help/index.html#supt

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