Device and process for refueling containers with pressurized gas
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Solution Overview
Problem
Existing hydrogen refuelling systems face challenges in maintaining sufficient cooling power, particularly when thermal inertia is insufficient, and in managing rapid changes in cooling demand, which can lead to inefficient use of cooling energy and fluctuations in refrigerant temperature.
Innovation Solution
The system employs an electronic controller to switch the compressor on and off based on predefined temperature thresholds, using a variable speed compressor and bypass conduit to regulate refrigerant flow and pressure, ensuring efficient cooling power delivery and maintaining superheat levels, even during standby modes and varying refuelling demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the refrigeration system operates continuously to maintain cooling power, then sufficient cooling capacity is ensured, but energy consumption increases and system wear accelerates
Solution Approach 1:
The system pre-cools the heat exchanger during standby mode before refuelling demand occurs, ensuring cooling capacity is ready in advance. This allows the compressor to be turned off during extended standby periods while maintaining the ability to provide full cooling power when needed.
Solution Approach 2:
The control unit periodically monitors heat exchanger temperature and activates the compressor only when temperature exceeds the threshold or refuelling is detected. This periodic checking and selective activation reduces energy consumption while ensuring cooling power is available when needed.
2Productivity
If the heat exchanger is continuously cooled to maintain low temperature, then cooling demand is met, but thermal energy is wasted during low demand periods
Solution Approach 1:
The control unit continuously monitors the heat exchanger temperature and compares it against a predetermined threshold. The compressor is activated only when feedback indicates temperature exceeds the threshold or when refuelling mode is detected, optimizing cooling delivery while avoiding energy waste during adequate temperature conditions.
Solution Approach 2:
The system dynamically adjusts compressor operation based on real-time temperature conditions and refuelling status. Instead of continuous operation, the compressor cycles on and off based on actual cooling demand, making the cooling system adaptive to varying operational conditions.
3Power
If the compressor operates at high capacity to meet peak cooling demand, then sufficient cooling power is provided, but energy consumption increases during low demand
Solution Approach 1:
The system applies partial cooling action during standby mode by pre-cooling the heat exchanger to a threshold temperature, which is sufficient to meet immediate cooling demand without requiring full compressor capacity. This partial action during standby prevents the need for high-capacity operation during low-demand periods.
Solution Approach 2:
The heat exchanger is pre-cooled during standby periods before peak demand occurs. This preliminary cooling action stores thermal energy in the heat exchanger mass, allowing the system to meet peak cooling demand without continuous high-capacity compressor operation, thereby reducing overall energy consumption.
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 ensures consistent and efficient cooling of hydrogen tanks, optimizing energy use by adjusting cooling power in real-time to match demand, maintaining stable refrigerant temperatures, and reducing the need for excessive thermal energy storage.
Implementation Method 1
a heat exchanger located in the transfer circuit and comprising a heat exchange section between the gas flowing in the transfer circuit and the evaporator section
Implementation Method 2
a condenser section, an expansion valve and an evaporator section, the refrigeration system comprising a cold source in heat exchange with the condenser section
Implementation Method 3
an expansion valve and an evaporator section
Data Source
AI summary
A device and process for refuelling containers with pressurized gas comprising a pressurized gas source, a transfer circuit intended to be removably connected to a container, the device comprising a refrigeration system for cooling the gas flowing from the gas source prior to its entering into the container and comprising a refrigerant cooling loop circuit comprising, arranged in series, a compressor, a condenser section, an expansion valve and an evaporator section, the refrigeration system comprising a cold source in heat exchange with the condenser section and a heat exchanger located in the transfer circuit and comprising a heat exchange section between the gas flowing in the transfer circuit and the evaporator section, the device comprising an electronic controller configured to switch the refrigeration system in first standby mode when the device is not refuelling a container wherein the compressor is switched off when the temperature of the heat exchanger is equal or below a predefined first standby temperature threshold and for started and operated for producing cooling power and cooling the heat exchanger when the sensed temperature of the heat exchanger is above a second standby threshold temperature.