Apparatus and process for pre-liquefaction fluid processing for improved liquefaction operations

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Solution Overview

Problem

Existing hydrogen liquefaction processes face challenges in operational flexibility and efficiency due to inconsistent renewable power availability, leading to high operational costs and energy consumption.

Innovation Solution

A control scheme is implemented to split the hydrogen feed into multiple fractions and distribute them to a train of liquefiers based on empirical data, ambient temperature, maintenance scheduling, and pre-selected criteria, using flow splitting mechanisms and a model predictive controller to ensure each liquefier operates at minimum capacity, minimizing power usage and fluctuations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hydrogen feed is distributed to multiple liquefiers without optimized control, then liquefaction capacity is increased, but power consumption and operational costs increase

Engineering Contradiction:

Improveliquefaction capacityVSAvoidpower consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts the distribution of hydrogen feed to multiple liquefiers based on real-time operational conditions, including ambient temperature variations and actual liquefaction efficiency data. This dynamic control allows the system to optimize power consumption by directing feed to liquefiers operating at peak efficiency while maintaining overall liquefaction capacity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system incorporates feedback mechanisms that continuously monitor ambient temperature, liquefaction efficiency, and power consumption across multiple liquefiers. This feedback enables the system to adapt feed distribution in real-time, ensuring optimal energy utilization while maintaining high productivity.

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If feed distribution is frequently adjusted to account for momentary feed availability changes, then operational flexibility is improved, but liquefier stability and efficiency decrease due to ramping up/down processes

Engineering Contradiction:

Improveoperational flexibilityVSAvoidliquefier stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system incorporates a dead band control mechanism that filters out momentary fluctuations in feed availability before triggering liquefier adjustments. By establishing predetermined thresholds and time delays, the system avoids unnecessary ramping operations for transient changes, thereby maintaining liquefier stability while still responding to sustained feed availability changes.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If green hydrogen production relies on renewable power sources, then environmental sustainability is improved, but operational consistency deteriorates due to inconsistent power availability

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidoperational consistency

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The system dynamically adapts feed distribution to multiple liquefiers based on real-time renewable power availability and ambient temperature conditions. This dynamic adjustment allows the system to maintain operational consistency despite the intermittent nature of renewable power sources, while continuing to utilize green hydrogen production for environmental sustainability.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances operational flexibility and energy efficiency by 1-5%, reducing power consumption and operational costs, allowing for higher hydrogen production rates and more economical processing.

Implementation Method 1

a pre-liquefaction system positioned between the source of the feed and the train of liquefiers so that the pre-liquefaction system is optimizable independent of the fractionation of the flow of feed for providing the portions of the feed to the different liquefiers

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS12535267B2Apparatus and process for pre-liquefaction fluid processing for improved liquefaction operations

Publication Date: 2026.01.27 AIR PROD & CHEM INC

AI summary

An apparatus and process for processing of a fluid (e.g. hydrogen) for liquefaction can permit a reduction in power consumption and also an improvement in operational efficiency in flexibility. Embodiments can be configured to account for large variations in feed to be provided for liquefaction and also permit operational cost reductions associated with liquefaction processing so the overall power consumption and operational cost for liquefaction can be greatly reduced while also providing improved operational flexibility. For instance, embodiments can be configured to feed a fluid to multiple liquefiers of a train of liquefiers based on a pre-selected set of feed routing criteria for improving power consumption and providing greater operational flexibility for liquefaction operations.