Two-Stage Hydrogen Cooling Station for Precise Refueling Temperature Control
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Solution Overview
Problem
Current hydrogen supply stations lack the capability to cool hydrogen with high efficiency and precision, which is essential for continuous and stable hydrogen supply to fuel-cell vehicles.
Innovation Solution
A cooled-hydrogen supply station is designed with a first and second coolant passage, water-cooled refrigerator units, and heat exchangers to cool hydrogen to a temperature range of −43° C. to −20° C., utilizing flon and potassium formate solution as coolants, with a hydrogen cooling power of 13.5 kW to 16.5 kW, and a feedback control system for precise temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional cooling methods are used for hydrogen supply, then hydrogen can be supplied to fuel-cell vehicles, but the cooling efficiency is insufficient and energy consumption is high
Solution Approach 1:
The cooling system is divided into multiple independent coolant passages (first coolant passage with water-cooled refrigerator unit, second coolant passage with heat exchangers) that can operate semi-independently. This segmentation allows optimized heat removal at different stages of the cooling process, improving overall cooling efficiency while reducing energy consumption through targeted cooling zones.
Solution Approach 2:
A two-stage coolant system is introduced as an intermediary between the hydrogen and the refrigeration source. The first coolant (in contact with refrigerator) transfers heat to the second coolant, which in turn cools the hydrogen. This intermediary system enables more efficient heat transfer compared to direct cooling, reducing energy consumption while maintaining high cooling efficiency.
2Reliability
If hydrogen cooling is implemented, then continuous hydrogen supply to fuel-cell vehicles is enabled, but the temperature control precision is insufficient
Solution Approach 1:
Temperature sensors are installed in the hydrogen passage to detect hydrogen temperature in real-time. The control unit receives this feedback and adjusts the operation of the water-cooled refrigerator unit and heat exchangers accordingly, enabling precise temperature control within the range of -43°C to -20°C and ensuring stable, reliable hydrogen supply.
Solution Approach 2:
The cooling system is designed with dynamic adjustability through the control unit, which can modify the operation parameters of the refrigerator unit and heat exchangers based on real-time temperature conditions. This dynamic control enables precise maintenance of hydrogen temperature within the specified range, improving both reliability and temperature control precision.
3Speed
If high cooling power is applied to cool hydrogen rapidly, then hydrogen supply speed increases, but energy consumption increases beyond acceptable levels
Solution Approach 1:
The cooling system operates in periodic cycles through the water-cooled refrigerator unit, which intermittently removes heat from the first coolant. This periodic refrigeration action, combined with the thermal energy storage capacity of the coolant system, enables rapid hydrogen cooling at high supply speeds while averaging out energy consumption over time, preventing excessive peak power demands.
Solution Approach 2:
The first coolant is pre-cooled by the water-cooled refrigerator unit before contacting the hydrogen through the heat exchangers. This preliminary cooling action prepares the coolant to efficiently absorb heat from the hydrogen, enabling rapid cooling at high supply speeds while minimizing the total energy required compared to direct high-power cooling of hydrogen.
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 achieves efficient and precise hydrogen cooling, allowing for continuous supply to fuel-cell vehicles with a flow rate of 4.5 kg to 5.5 kg per 3 minutes, and enables energy-efficient operation by selecting between two modes based on supply probability, maintaining cooling precision within ±3° C. of the set temperature.
Implementation Method 1
a water-cooled refrigerator unit disposed on a part of the first coolant passage to enable cooling of the first coolant
Implementation Method 2
a first heat exchanger enabling cooling of the second coolant by the first coolant, between another part of the first coolant passage and a part of the second coolant passage
Implementation Method 3
a second heat exchanger enabling cooling of the hydrogen by the second coolant, between another part of the second coolant passage and a part of the hydrogen passage; the hydrogen is cooled down to a temperature range of between −43° C. and −20° C. by the second heat exchanger
Data Source
AI summary
A cooled-hydrogen supply station includes: a first coolant passage through which a first coolant circulates; a water-cooled refrigerator unit disposed on a part of the first coolant passage to cool the first coolant; a second coolant passage through which a second coolant flows; a first heat exchanger for cooling the second coolant by the first coolant, between another part of the first coolant passage and a part of the second coolant passage; a hydrogen storage unit; a hydrogen passage for transporting hydrogen stored in the hydrogen storage unit; and a second heat exchanger for cooling the hydrogen by the second coolant, between another part of the second coolant passage and a part of the hydrogen passage. The hydrogen is cooled down to a temperature of −43° C. to −20° C. by the second heat exchanger, and a hydrogen cooling power for cooling hydrogen to −40° C. is between 13.5 kW and 16.5 kW.