Gas Filling Control Device for Variable Demand
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Solution Overview
Problem
Filling stations for pressurized gas tanks, particularly hydrogen, face inefficiencies due to variable demand patterns, leading to oversized equipment and increased costs, electricity consumption, and compressor wear, as they must be designed to handle peak demands with minimal pressure sources, resulting in underutilization during lower demand periods.
Innovation Solution
A device with an electronic control system that adjusts gas source usage based on predefined and dynamically updated demand schedules, switching between high and low pressure sources to optimize performance and reduce energy consumption, using sensors and predictive algorithms to manage compressor operation and buffer storage filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the station is sized to absorb peak demand with higher flow rate compressors and larger storage capacities, then the station can handle high filling requests, but the station becomes oversized for the rest of the day resulting in higher purchase and operation costs
Solution Approach 1:
The patent applies dynamics by making the compressor flow rate adjustable based on real-time demand. The control system dynamically modifies the compressor's operating point along its performance curve, switching between high flow rate mode during peak demand and reduced flow rate mode during low demand periods. This resolves the contradiction by allowing the station to maintain high peak capacity while avoiding the constant energy consumption of an oversized compressor running at partial load.
Solution Approach 2:
The patent changes the operating parameters of the compressor system by introducing variable flow rate capability. The control system adjusts parameters such as compressor speed, valve positions, and buffer storage pressure levels to optimize performance for different demand conditions. This allows the same equipment to serve both peak and off-peak requirements efficiently, eliminating the need for permanently oversized equipment.
2Reliability
If the compressor is oversized to provide highest flow rate with lowest available pressure, then the station can meet peak demand, but the compressor and station are oversized the rest of the time when gas source pressure is higher than minimum pressure
Solution Approach 1:
The system dynamically adjusts compressor performance based on source pressure conditions. When source pressure is low, the compressor operates at high flow rate to ensure adequate supply. When source pressure is high, the compressor reduces its flow rate contribution, allowing the system to utilize the higher pressure source more effectively. This dynamic adaptation eliminates the need for permanently oversized compressors while maintaining reliability across varying pressure conditions.
3Productivity
If the station uses highest pressure sources during peak demand, then filling performance is maximized, but electricity consumption increases and compressor wear increases
Solution Approach 1:
The patent implements periodic action by alternating between high-performance mode (using highest pressure sources and high compressor flow rate) during peak demand periods and energy-saving mode (using lower pressure sources and reduced compressor flow rate) during off-peak periods. The control system monitors demand patterns and switches operating modes accordingly, achieving high filling speeds when necessary while reducing electricity consumption and compressor wear during lower demand periods.
4Adaptability or versatility
If the station operates with variable demand patterns, then it can adapt to actual usage, but equipment must be oversized for peak demand resulting in underutilization during lower demand periods
Solution Approach 1:
The system achieves adaptability through dynamic control of compressor flow rate and source selection. The control system continuously monitors demand patterns, source pressure levels, and system state, then adjusts operating parameters in real-time. This allows the station to fully utilize available resources during low demand periods rather than operating with fixed oversized capacity, thereby reducing energy underutilization while maintaining the ability to respond to peak demand.
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
The solution reduces equipment costs, electricity consumption, and compressor wear by intelligently selecting gas sources based on demand patterns, optimizing performance during peaks and conserving resources during lows, thereby enhancing operational efficiency and reducing maintenance needs.
Implementation Method 1
The circuit further comprises at least one compressor
Implementation Method 2
The device comprising a set of sensors for measuring the pressure within the sources and the buffer storages
Data Source
Figure 1
AI summary
A device for filling a tank or tanks with pressurised gas comprising a circuit (2) comprising a plurality of upstream ends (3) connected respectively to separate pressurised gas sources (4, 5, 6), at least one compressor (7), at least one buffer storage (8, 9, 10), a set of controlled valves (13, 4, 15, 16) and at least one downstream end (11) intended to be connected to the tank(s) (12) to be filled, the device (1) further comprising an electronic control member (35) configured to control the valves (13, 14, 15, 16) and/or the compressor (7) in order to ensure a transfer of gas into the tank (12) from at least one source (4, 5, 6) and/or at least one buffer storage (8, 9, 10) and/or via the compressor (7), the device (1) comprising a set of sensors (24, 25, 26, 28, 29, 30) for measuring the pressure in the sources (4, 5, 6) and the buffer storages (8, 9, 10), the control member (35) comprising a member (27) for receiving or generating a signal representative of the filling demand from a relatively high demand to a relatively low demand, the control member (35) being configured to ensure the transfer of gas into the tank (12) according to at least a first transfer mode using the source having the highest pressure and a second transfer mode using a source having a pressure lower than this highest pressure in response, respectively, to a relatively high or low filling demand.