Hydrogen Refuelling Cooling System with Refrigerant Bypass Control
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Solution Overview
Problem
Existing hydrogen refuelling systems face challenges in maintaining consistent cooling due to insufficient thermal inertia in heat exchangers, leading to fluctuations in cooling demand and inefficiencies, especially during rapid changes in cooling power requirements.
Innovation Solution
Incorporating a bypass conduit with a regulating valve in the refrigerant cooling loop circuit, allowing for control of refrigerant flow and compressor speed to manage refrigerant temperature and pressure, ensuring sufficient superheat and efficient cooling power delivery, even during rapid load changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a compact diffusion bonded heat exchanger is used, then the device size is reduced, but the thermal inertia becomes insufficient to respond to rapid changes in cooling demand
Solution Approach 1:
The system pre-cools the heat exchanger during standby mode before refuelling begins, so that cooling capacity is already available when needed. This preliminary action ensures rapid response to cooling demand without requiring large thermal inertia in the heat exchanger structure itself.
Solution Approach 2:
The patent replaces reliance on passive thermal inertia with an active control system that uses sensors and actuators to dynamically adjust refrigerant flow and compressor operation, enabling rapid response to cooling demands without requiring large thermal mass.
2Use of energy by moving object
If the refrigeration system operates at low load during standby or partial refuelling, then energy consumption is reduced, but the system cannot meet sudden full cooling demand
Solution Approach 1:
During standby mode, the system performs preliminary cooling of the heat exchanger to a predetermined temperature threshold. This prepares the system to immediately meet full cooling demand when refuelling begins, without requiring continuous high-power operation and thus reducing energy consumption during idle periods.
Solution Approach 2:
The system dynamically adjusts refrigerant flow rate and compressor speed based on real-time cooling demand signals from sensors. This allows the system to operate at low power during standby and partially load during refuelling, while maintaining the capability to rapidly scale up to full cooling power when needed.
3Productivity
If cooling power is increased to meet high demand, then refuelling speed is improved, but temperature and pressure fluctuations increase
Solution Approach 1:
Temperature and pressure sensors continuously monitor the refrigeration system and provide feedback signals to the controller. The controller adjusts refrigerant flow rate and compressor speed in real-time based on this feedback, maintaining stable operating conditions even during high-power cooling operations and rapid load changes.
Solution Approach 2:
The system uses dynamic control of refrigerant flow and compressor operation to rapidly adjust cooling power output. This allows the system to meet high cooling demands for fast refuelling while actively managing temperature and pressure fluctuations through real-time parameter adjustment.
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 solution enables precise control of cooling power, maintaining consistent refrigerant temperature and pressure, and efficiently managing rapid changes in cooling demand, enhancing the stability and efficiency of hydrogen refuelling processes.
Implementation Method 1
a compressor (8)
Implementation Method 2
a condenser section (9) in heat exchange with a cold source (12)
Implementation Method 3
an expansion valve (10)
Implementation Method 4
an evaporator section (11)... a heat exchanger (7) located in the transfer circuit (4) and comprising a heat exchange section between the gas flowing in the transfer circuit (4) and the evaporator section (11)
Implementation Method 5
a bypass conduit (13)... a bypass regulating valve (15) for controlling the flow of refrigerant flowing into the by-pass conduit (13)
Implementation Method 6
a heat exchanger (7) located in the transfer circuit (4) and comprising a heat exchange section between the gas flowing in the transfer circuit (4) and the evaporator section (11)
Data Source
Figure 1~4
Figure 5~9
AI summary
A device and process for refuelling containers with pressurized gas comprising a pressurized gas source (2), a transfer circuit (4) comprising one upstream end (5), the device (1) comprising a refrigeration system for cooling the gas flowing from the gas source (2) prior to its entering into the container (3), the refrigeration system comprising a refrigerant cooling loop circuit (20) comprising, arranged in series, a compressor (8), a condenser section (9), an expansion valve (10) and an evaporator section (11), the refrigeration system comprising a cold source (12) in heat exchange with the condenser section (9) and a heat exchanger (7) located in the transfer circuit (4) and comprising a heat exchange section between the gas flowing in the transfer circuit (4) and the evaporator section (11), the refrigerant cooling loop circuit (20) comprising a bypass conduit (13) comprising an upstream end connected to the outlet of the compressor (8) and a downstream end connected to the refrigerant cooling loop circuit (20) upstream the compressor (8) inlet and bypassing the condenser section (9) and expansion valve (10), the device comprising a bypass regulating valve (15) for controlling the flow of refrigerant flowing into the by-pass conduit (13).