Two-Tier Tube-Trailer System for Hydrogen Refueling Cost Reduction
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Solution Overview
Problem
Current hydrogen refueling systems for tube-trailers and compressors face challenges in reducing refueling costs, maximizing storage utilization, minimizing pressure cycling of pressure vessels, and simplifying controls while maintaining high payload efficiency.
Innovation Solution
A two-tier fuel supply system with separate control units for each tier of pressure vessels and a high-pressure buffer storage, where hydrogen is selectively consolidated between tiers and the buffer storage based on predefined pressures to optimize refueling operations, reduce pressure cycling, and simplify controls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-tier fuel supply system is used, then the device complexity is reduced, but the storage utilization is not maximized and pressure cycling cannot be limited
Solution Approach 1:
The fuel supply system is divided into two independent tiers, each with its own control unit. Tier 1 manages high-pressure buffer storage while Tier 2 manages tube-trailer pressure vessels. This segmentation allows independent optimization of each tier's operation, maximizing storage utilization while preventing excessive pressure cycling in any single tier.
2Productivity
If pressure vessels are frequently cycled to maintain fuel supply, then the refueling cost is reduced through better utilization, but the reliability decreases due to increased pressure cycling
Solution Approach 1:
Tier 2 pressure vessels are pre-filled and staged in advance. When Tier 1 buffer storage pressure decreases, the control system automatically consolidates hydrogen from Tier 2 into Tier 1, rather than cycling Tier 1 vessels frequently. This preliminary staging of fuel in Tier 2 protects Tier 1 vessels from excessive pressure cycling while maintaining continuous refueling capability.
3Quantity of substance
If a two-tier system with separate control units is implemented, then storage utilization is maximized and pressure cycling is limited, but the device complexity increases
Solution Approach 1:
Each control unit (104, 106) is designed to be multi-functional, managing both fuel consolidation and pressure regulation within its tier. The control units can operate independently or in coordination, providing universal functionality that reduces the need for additional specialized components, thereby limiting complexity growth despite the two-tier architecture.
4Productivity
If tube-trailer payload is maximized, then the refueling efficiency is improved, but the number of fittings and control complexities increase
Solution Approach 1:
Multiple pressure vessels within each tier are merged into a unified fuel supply system through common piping and control. This merging allows the system to treat distributed storage capacity as a single logical unit, maximizing payload utilization while avoiding the complexity of individually controlling each vessel. The consolidation reduces the effective number of fittings needed compared to a fully distributed control architecture.
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 refueling costs, maximizes storage utilization, limits pressure vessel cycling, and enhances payload efficiency by ensuring high compressor throughput and minimizing the number of fittings and control complexities.
Implementation Method 1
at least one compressor coupled to the first tanks by a first control unit and to a high pressure buffer storage having a predefined capacity by a second control unit
Implementation Method 2
the first tanks and the high pressure buffer storage by a pressure control valve
Data Source
AI summary
A method and system are provided for operating refueling station tube-trailers and compressors to reduce hydrogen refueling cost. A hydrogen refueling station includes a two-tier fuel supply of pressure vessels on a refueling station tube-trailer, with a first tier and a second tier of pressure vessels including at least one or more pressure vessels connected together. A separate control unit is coupled to the first tier and the second tier of pressure vessels with each of the control units coupled to a compressor. The compressor is coupled to a high pressure buffer storage by a separate control unit. In operation, pressure is monitored in the each tier. Hydrogen is consolidated selectively between the first tier of pressure vessel banks, the second tier pressure vessels, and the high pressure buffer. Based upon monitored pressures, one of the first tier of pressure vessels, the second tier pressure vessel banks, and the high pressure buffer is used to refuel vehicles.