Hydrogen Refueling Station Bypass Valve Control
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Solution Overview
Problem
Existing hydrogen refueling stations have high power consumption and long refueling times due to inefficient hydrogen flow management.
Innovation Solution
A hydrogen refueling station design that includes a hydrogen storage module, a compressor with a controller, and dispensing modules with pressure detection and bypass valves, allowing for simultaneous refueling of vehicles with different tank pressures without the need for high-pressure storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If hydrogen is pressurized in a compressor before storage, then high-pressure storage is achieved, but power consumption increases and refueling time increases
Solution Approach 1:
The system pre-pressurizes hydrogen in the compressor during idle periods or when demand is low, storing it in the high-pressure buffer tank. This preliminary action ensures that high-pressure hydrogen is already available when refueling demand arises, eliminating the need for prolonged compressor operation during peak demand and reducing overall power consumption.
Solution Approach 2:
The compressor operates continuously or near-continuously at an optimized setpoint pressure, maintaining a steady supply of pressurized hydrogen in the buffer tank. This continuous operation at optimal efficiency points reduces cyclic startup/shutdown losses and maintains stable power consumption, while the buffer tank ensures uninterrupted supply to dispensers.
2Productivity
If hydrogen is pressurized in a compressor before dispensing, then refueling speed increases, but refueling time increases due to pressure buildup delays
Solution Approach 1:
The high-pressure buffer tank is pre-filled with pressurized hydrogen before refueling demand occurs. When a vehicle arrives for refueling, the dispensers can immediately draw from this pre-prepared high-pressure supply, eliminating the time delay associated with real-time compression and pressure buildup during the refueling process.
Solution Approach 2:
The high-pressure buffer tank acts as an intermediary storage element between the compressor and the dispensers. It decouples the compression process from the dispensing process, allowing the compressor to operate independently to maintain buffer pressure while dispensers rapidly deliver hydrogen to vehicles without waiting for compression cycles.
3Device complexity
If a single compressor is used for multiple dispensers, then system complexity reduces, but ability to simultaneously refuel vehicles with different pressure requirements decreases
Solution Approach 1:
The system segments the hydrogen supply into two distinct pressure pathways: a high-pressure path from the buffer tank for rapid refueling, and a low-pressure path from the storage tank through the compressor for vehicles requiring pressure buildup. This segmentation allows a single compressor to serve multiple dispensers with different requirements by routing hydrogen through appropriate pressure zones.
Solution Approach 2:
The single compressor is designed to fulfill multiple functions: it can pressurize hydrogen for the high-pressure buffer tank, it can directly supply pressurized hydrogen to dispensers for immediate use, and it can adjust its output to match varying demand patterns. The control system enables the compressor to dynamically switch between these modes, providing universal service to all dispensers regardless of their instantaneous pressure requirements.
4Speed
If high-pressure storage tanks are used, then immediate refueling is enabled, but system costs increase
Solution Approach 1:
Instead of providing full high-pressure storage capacity for all possible simultaneous refueling scenarios, the system implements a partial high-pressure buffer that meets the majority of demand. The buffer is sized to handle typical peak demand, with the compressor serving as supplemental capacity for extraordinary demands, thus achieving rapid refueling response without the prohibitive cost of oversized high-pressure storage infrastructure.
Solution Approach 2:
The high-pressure buffer tank serves as an intermediary that provides immediate response capability without requiring large volumes of high-pressure storage. It acts as a buffer that can be quickly filled by the compressor and quickly dispensed to vehicles, providing the speed advantage of high-pressure storage while using a smaller, more cost-effective tank capacity.
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 power consumption and refueling time by maintaining constant compressor operation, allowing for immediate refueling of multiple vehicles and eliminating the need for high-pressure storage, thereby reducing costs and increasing system longevity.
Implementation Method 1
a compressor (19) configured for compressing hydrogen from a first pressure to a second pressure
Implementation Method 2
a pressure detection means (14) configured for detecting a pressure in a compressor outlet line (8)
Implementation Method 3
a bypass valve (16) configured for bypassing the compressor (19) when a pressure in an outlet line (8) of the compressor reaches a threshold pressure
Data Source
AI summary
A hydrogen refueling station including a first and a second dispensing module having first and second dispensing pressure detection means, where supply lines are fluidly connecting a storage module to an inlet compressor line and a compressor outlet line is fluidly connecting an outlet of the compressor to a dispensing line and thereby to the first and/or second dispensing module via output compressor valves, cascade lines are fluidly connecting the hydrogen storage module and the dispenser modules thereby configured for bypassing the compressor, where a controller is configured for controlling valves and thereby a fluid path from the hydrogen storage module to the dispensing modules, the controller is configured for controlling a bypass valve based on feedback from pressure detection means, from a first dispensing pressure detection means or from a second dispensing pressure detection means to establish a required pressure in the compressor outlet line.