Parallel-Cylinder Ionic-Fluid Compression for Low-Heat Hydrogen Refueling
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Solution Overview
Problem
Existing gas compressors, particularly those used in hydrogen filling stations for heavy vehicles, face inefficiencies in energy consumption and maintenance due to high compression pressures, generating excessive heat and requiring complex maintenance, making them unsuitable for containerized solutions.
Innovation Solution
A method utilizing ionic fluid compression with parallel compression cylinders actuated by a radial piston pump, allowing for efficient, low-heat generation and variable operation, with optional buffer tanks and heat exchangers for cooling and fluid recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If piston compressors are used to compress hydrogen to high pressures (700 bar and above), then the required compression pressure is achieved, but high compression energy is consumed and high temperatures are generated that stress compressor seals
Solution Approach 1:
The compression process is divided into multiple parallel compression cylinders instead of using a single large compressor. Each cylinder handles a portion of the total compression load, allowing for more efficient energy utilization and reduced heat generation per cylinder while achieving the required high outlet pressure of 700 bar or above
Solution Approach 2:
The patent employs a hydraulic coupling mechanism where a hydraulic motor drives the compression pistons through hydraulic fluid transmission. This hydraulic drive system allows for smoother operation, better control of compression timing, and reduced mechanical friction compared to direct mechanical drive, thereby reducing overall compression energy consumption
2Stress or pressure
If piston compressors are used to compress hydrogen to high pressures, then the required compression pressure is achieved, but high temperatures are generated that place stress on compressor seals
Solution Approach 1:
By dividing the compression into multiple parallel cylinders, each cylinder processes a smaller volume of gas, reducing the temperature rise per compression stroke. The parallel arrangement also allows for better heat dissipation across the entire compression system, preventing excessive temperature buildup that would stress seals
Solution Approach 2:
The hydraulic coupling system enables continuous and smooth operation of the compression cylinders, avoiding abrupt starts and stops that generate heat. The hydraulic fluid acts as a heat transfer medium, continuously removing heat from the compression chambers and maintaining lower operating temperatures
3Power
If traditional compressors are used with high connected load, then compression capability is sufficient, but a lot of cooling capacity is required
Solution Approach 1:
The hydraulic drive system uses hydraulic fluid that circulates through the compression cylinders, serving dual purposes: transmitting mechanical power to the pistons and simultaneously acting as a cooling medium. This integrated approach reduces the need for separate cooling systems and minimizes energy loss to heat
4Productivity
If large piston compressors are used for high-pressure compression, then the required compression capacity is achieved, but they are too large for containerized solutions
Solution Approach 1:
The compression system is divided into multiple smaller parallel compression cylinders that can be arranged in a compact configuration. Each cylinder is smaller in size but collectively they provide the required total compression capacity, enabling the entire system to fit within containerized dimensions while maintaining high productivity
Solution Approach 2:
Instead of using a single large horizontal compressor, the patent arranges multiple smaller cylinders in a vertical or multi-level configuration. This dimensional reorganization allows the compression system to achieve the same capacity in a more compact footprint that fits within standard shipping containers
5Power
If traditional compressors are used for high-pressure compression, then compression capability is sufficient, but complex maintenance work is required when the entire compressor is out of service
Solution Approach 1:
The compression system consists of multiple independent parallel cylinders, each with its own drive mechanism. This modular design allows individual cylinders to be maintained or replaced without shutting down the entire compression system, significantly reducing maintenance complexity and downtime while maintaining overall compression capability
Solution Approach 2:
The parallel cylinder arrangement enables periodic maintenance of individual units while others continue operating. This allows for scheduled maintenance of one cylinder while the others provide continuous compression service, making maintenance less disruptive and more manageable
6Power
If traditional compressors are used for high-pressure compression, then compression capability is sufficient, but no refueling is possible during maintenance
Solution Approach 1:
The modular parallel cylinder design allows the compression system to operate with only a subset of cylinders active at any given time. During maintenance of one or more cylinders, the remaining cylinders continue to provide compression capability, enabling refueling operations to proceed without interruption
Solution Approach 2:
The system dynamically adjusts the number of active compression cylinders based on maintenance requirements and refueling demand. This dynamic operation ensures that compression capability is maintained at sufficient levels even when some cylinders are under maintenance, preventing refueling interruptions
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 energy-efficient gas compression with reduced heat generation, simplified maintenance, and flexible operation, enabling high-pressure hydrogen refueling without lengthy interruptions.
Implementation Method 1
the fluid and/or pistons of the compression cylinders being moved by a pump
Implementation Method 2
with optional buffer tanks and heat exchangers for cooling and fluid recycling
Data Source
Figure 1
AI summary
The invention relates to a method for compressing gas (a), in particular hydrogen, wherein the gas is obtained and divided into several parallel partial streams, and wherein each partial stream is fed to one of several compression cylinders (106.1, 106.1, 106.3), wherein the several compression cylinders are assigned to the same pressure stage, wherein gas is compressed in the compression cylinders (106.1, 106.1, 106.3) using a fluid (c), in particular an ionic fluid, wherein the fluid and/or pistons of the compression cylinders are moved by means of a pump (120), and wherein the compressed gas is combined to form an output stream, and wherein the compressed gas (b) of the output stream is provided for further use. The invention also relates to a corresponding system (100).