Hydrogen Compressor Cooling Through Recirculated Gas Channels

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Solution Overview

Problem

Conventional compressors fail to meet the high-pressure and high-flow rate requirements for hydrogen fueling vehicles due to heat-related damage to sealing components, and traditional cooling systems risk contaminating the compressed hydrogen or allowing it to escape.

Innovation Solution

A cooling system using hydrogen as a coolant, distributed through intricate channels formed by additive manufacturing, absorbs heat from compressor components and recirculates heated hydrogen back to a cold box for cooling, maintaining the integrity and purity of the compressed gas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional fluid or water-based cooling systems are used to reduce heat damage on compressor components, then heat mitigation is improved, but the hydrogen being compressed can be contaminated or escape via cooling channels

Engineering Contradiction:

Improveheat damage on compressor componentsVSAvoidcontamination of hydrogen and gas escape

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent uses the compressed hydrogen gas itself as an intermediary cooling medium. The cooled hydrogen gas is circulated through channels in the pressure packer and piston rod, absorbing heat without contaminating the main hydrogen stream. This self-cooling approach eliminates the need for external water or fluid cooling systems that could cause contamination.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cooling channels are specifically configured in the pressure packer and piston rod where heat generation is most critical. The channels are positioned to provide localized cooling at the sealing surfaces and high-friction areas, ensuring heat mitigation precisely where needed without affecting the overall hydrogen purity.

Inventive Principle:

Principle #3Local quality

2Productivity

If conventional compressors are used, then they can operate with simple cooling systems, but they cannot meet the high pressure (800-900 bar) and high flow rate (800-1200 kg/hr) requirements due to heat damage to seals

Engineering Contradiction:

Improveflow rate and pressure capabilityVSAvoidseal durability under high heat

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The hydrogen gas is pre-cooled before entering the compression chamber and continuously circulated through cooling channels during operation. This preliminary and ongoing cooling action prevents heat buildup that would otherwise damage seals, enabling the compressor to reliably operate at high pressures and flow rates.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The compressor uses its own compressed hydrogen output to cool itself through the pressure packer and piston rod channels. This self-service cooling system eliminates external cooling requirements and allows the compressor to maintain seal integrity at high operating conditions, achieving both high productivity and reliability.

Inventive Principle:

Principle #25Self-service

3Device complexity

If simple cooling channels are used, then device complexity is reduced, but heat transfer surface area is insufficient to effectively cool the compressor components

Engineering Contradiction:

Improvecooling system structureVSAvoidheat transfer efficiency

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The cooling channels are configured in three-dimensional paths within the pressure packer and piston rod, maximizing surface area contact with heated surfaces. The channels extend through multiple dimensions of the components, providing extensive heat transfer area without adding external cooling apparatus complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 system effectively manages heat without contaminating the compressed hydrogen, ensuring safe operation and efficient delivery of hydrogen fuel at high pressures and flow rates, while avoiding cross-contamination and maintaining seal integrity.

Implementation Method 1

Compressed hydrogen gas can be distributed within the injection channels into fluidic interface with heated portions of the compressor, such as a reciprocating piston rod, and can absorb heat from the reciprocating piston rod

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The hydrogen gas can absorb the heat and heat laden hydrogen gas can be removed from the pressure pack and the compressor

Methodology Applied

Scientific EffectThermal convection: Convection

Data Source

PatentUS12404855B2Cooling system for a hydrogen compressor

Publication Date: 2025.09.02 NUOVO PIGNONE TECH SRL

AI summary

A hydrogen cooled pressure packer, systems, and methods of operation are provided. The pressure packer can include a flange portion and a plurality of packing cups coupled to the flange portion. One or more packing cups of the plurality of packing cups include at least one injection channel extending therethrough and terminating in at least one injection port. The pressure packer can also include a seal abutted with at least one packing cup of the plurality of packing cups. The pressure packer can be configured for use in a hydrogen compressor operable within a hydrogen vehicle refueling facility.