Hydrogen Refueling Station Control for Fewer Compressor Start-Stops

Solution Overview

Problem

Existing hydrogen refueling stations experience high power consumption and compressor wear due to frequent start/stops, which are costly and inefficient, especially during periods of varying refueling demand.

Innovation Solution

A control system for hydrogen refueling stations that optimizes compressor operation by using a high frequency tank profile during rush hours and a low frequency tank profile during off-peak times, managing pressure distribution across multiple vessels and adjusting compressor speed to minimize start/stops and optimize energy use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the compressor is stopped and restarted frequently to match refueling demand, then the refueling station can adapt to varying demand patterns, but power consumption increases and compressor wear increases

Engineering Contradiction:

Improveadaptability to varying refueling demandVSAvoidpower consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The system performs preliminary actions by storing hydrogen in accumulators during periods of low demand, so that when demand increases, the pre-stored hydrogen can be dispensed without requiring the compressor to start frequently. This advance preparation reduces both power consumption and mechanical wear.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The compressor operates continuously or for extended periods to fill accumulators, maintaining a steady supply of pressurized hydrogen. This continuous operation is more efficient than frequent start-stop cycles, reducing energy consumption and mechanical stress while ensuring ready availability of hydrogen for refueling.

Inventive Principle:

Principle #20Continuity of useful action

2Adaptability or versatility

If the compressor is stopped and restarted frequently to match refueling demand, then the refueling station can adapt to varying demand patterns, but compressor wear increases

Engineering Contradiction:

Improveadaptability to varying refueling demandVSAvoidcompressor wear

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system performs preliminary actions by storing hydrogen in accumulators during periods of low demand, so that when demand increases, the pre-stored hydrogen can be dispensed without requiring the compressor to start frequently. This advance preparation reduces both power consumption and mechanical wear.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The compressor operates continuously or for extended periods to fill accumulators, maintaining a steady supply of pressurized hydrogen. This continuous operation is more efficient than frequent start-stop cycles, reducing energy consumption and mechanical stress while ensuring ready availability of hydrogen for refueling.

Inventive Principle:

Principle #20Continuity of useful action

3Use of energy by moving object

If accumulators are used to store hydrogen for later dispensing, then compressor start/stops are reduced and energy consumption decreases, but the system complexity increases

Engineering Contradiction:

Improveenergy consumptionVSAvoidsystem complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The hydrogen storage system is segmented into multiple accumulators that can be independently filled and dispensed from. This segmentation allows the system to manage hydrogen storage and distribution more efficiently, reducing the need for frequent compressor operation while maintaining manageable system complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The accumulators serve as intermediary storage devices between the compressor and the refueling dispensers. They buffer the system by storing pressurized hydrogen when demand is low and supplying it when demand is high, decoupling the compressor operation from refueling demand and reducing system complexity compared to direct compression during each refueling event.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces compressor start/stops, lowers energy consumption, and ensures efficient refueling by maintaining optimal compressor operation and pressure levels, extending equipment lifespan while adapting to varying demand patterns.

Implementation Method 1

a compressor (2) fluidly connected to a supply storage (5) and a dispenser (3)

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

a cooling system (12) fluidly connected to a supply storage (5) and a dispenser (3)

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS11105467B2Control of a hydrogen refueling station

Publication Date: 2021.08.31 NEL HYDROGEN AS

AI summary

The invention related to a system for control of a hydrogen refueling station. The control of the hydrogen refueling station is optimized according to a high frequency tank profile in a time period between time A and time B. The high frequency tank profile includes selecting a first of the plurality of vessels as supply to the compressor during at least part of the refueling of the vehicle tank, the selection is based on pressure of hydrogen gas in one or more vessels of the supply storage. The control of the hydrogen refueling station is furthermore optimized according to a low frequency tank profile in a time period between time C and time D. The low frequency tank profile includes preparing one or more hydrogen refueling station components to enable a plurality of vehicle tank refuelings in the subsequent time period between time A and time B.