Thermodynamic assessments of a novel integrated process for producing liquid helium and hydrogen simultaneously

Liquid helium and hydrogen are two precious cryogens with advanced applications in various energy research fields. However, producing these cryogens generally come with high-cost processes. In this research, Liquid hydrogen is obtained in two stages with the aid of a mixed refrigeration subprocess and helium cryogen. Also, liquid helium is obtained in three stages with the aid of helium upgrader, pressure swing adsorption, and helium liquefier subprocesses. The liquid helium is produced at 19.42 K, 195 kPa, and 6161 kgmole/h. Also, the liquid hydrogen is produced at 3.69 K, 110.3 kPa, and 17,970 kgmole/h. The novelties of this research can be described as the production of liquid helium and hydrogen simultaneously, low SEC, novel configuration, and production of liquid helium and hydrogen at near ambient pressure. Thermodynamic analyses show that the specific energy consumption, coefficient of performance, and figure of merit are equal to 18.96 kW h/kg, 0.03, and 0.37, respectively. Also, the exergy analysis shows that the exergy efficiency and exergy destruction in the whole process are equal to 67% and 4471 MW, respectively. Also, sensitivity analysis shows that increasing the PSA process efficiency positively impacts all process parameters like SEC, COP, FOM, and exergy efficiency.     

In-field Performance Evaluation of a Large Size Multistream Plate Fin Heat Exchanger Installed in a Helium Liquefier

Abstract

A large size multistream plate fin heat exchanger (MSPFHE) is developed for an in-house-developed modified Claude cycle-based helium liquefier. The development of this heat exchanger, including thermal sizing and mechanical design, is described in this article. A pressure drop analysis is also carried out to compute the pressure drops across various components of the MSPFHE. The MSPFHE, after fabrication, pressure and leak testing, is integrated with the rest of the process equipment and piping of the developed helium liquefier cold box. Experiments are conducted to evaluate the performance of the developed MSPFHE under different modes of operations of the helium liquefier. Experimental results are compared with the computed predictions based on the two-dimensional numerical model as well as the commercial software Aspen MUSE^TM and reported in this article. Good agreement between the computed and measured performances is observed during the field testing of the MSPFHE.     

Performance prediction of externally pressurized gas bearings for high-speed turbo-expander involving hydrogen,helium and air working fluids

High-speed hydrogen turbo-expander is widely employed in hydrogen liquefaction systems due to its high efficiency. The hydrogen bearings in high-speed turbo-expander are usually applied for low viscosity and pollution-free advantages. Nevertheless, the load capacity of hydrogen bearing is low and the research on maximizing the load capacity is limited by the complicated solution process and danger hydrogen experiment. The purpose of the paper is to easily and quickly acquire the load capacity of high-speed orifice externally pressurized hydrogen journal bearing for optimization of bearing performance. A new simple load capacity predicted model, that is universal for various working fluids involving hydrogen, helium and air, was proposed through the hydrostatic and hydrodynamic analysis. In the model, the evaluation indicators of hydrodynamic and hydrostatic effects were proposed. Based on the model, no numerical analysis and computer programming are needed to calculate the load capacity of journal bearing and numerous key design variables are considered. The results from the predicted model agree very well with those obtained from the finite difference method (FDM) technique. In view of the danger of hydrogen bearing experiment, the load capacity predicted model can be used to design the equivalent experiment of load capacity through substituting air for hydrogen working fluid.     

Effect of various inlet air cooling methods on gas turbine performance

Turbine air inlet cooling is one of many available commercial methods to improve the efficiency of an existing gas turbine. The method has various configurations which could be utilized for almost all installed gas turbines. This paper presents a comparison between two commons and one novel inlet air cooling method using turbo-expanders to improve performance of a gas turbine located at the Khangiran refinery in Iran. These methods have been applied to one of the refinery gas turbines located at the Khangiran refinery in Iran. Two common air cooling methods use evaporative media or a mechanical chiller. The idea behind the novel method is to utilize the potential cooling and power capacity of the refinery natural gas pressure drop station by replacing throttling valves with a turbo-expander. The study is part of a comprehensive program with the goal of enhancing gas turbine performance at the Khangiran gas refinery. Based on the results, it is found that using turbo-expanders is the most economically feasible option and so is recommended to be utilized for improving gas turbine performance at the Khangiran refinery.     

Second law analysis of hydrogen liquefiers operating on the modified Collins cycle

Hydrogen liquefaction systems have been the subject of intense investigations for many years. Some established gas liquefaction systems, such as the precooled Linde–Hampson systems, are not used for hydrogen liquefaction in part because of their relatively low efficiencies. Recently, more promising systems employing the modified Collins cycle have been introduced. This paper reports on second law analyses of a hydrogen liquefier operating on the modified Collins cycle. Two different modifications employing the cycle in question were attempted: (1) a helium‐refrigerated hydrogen liquefaction system and (2) a hydrogen‐refrigerated hydrogen liquefaction system. Analyses were carried out in order to identify potential areas of development and efficiency improvement. A computer code capable of computing system and component efficiencies; exergy losses; and optimum number and operating conditions of compressors, expanders, aftercoolers, intercoolers, and Joule–Thomson valves was developed. Evaluation of the thermodynamic and transport properties of hydrogen at different temperature levels was achieved by employing a hydrogen property code developed by researchers at the National Bureau of Standards (currently NIST). A parametric analysis was carried out and optimal decision rules pertaining to system component selection and design were reached. Economic analyses were also reported for both systems and indicated that the helium‐refrigerated hydrogen liquefier is more economically feasible than the hydrogen‐refrigerated hydrogen liquefier. Copyright © 2001 John Wiley & Sons, Ltd.     

Effect of ignition timing and compression ratio on the performance of a hydrogen–ethanol fuelled engine

This paper presents the results obtained of a compression ignition engine (modified to run on spark ignition mode) fuelled with hydrogen–ethanol dual fuel combination with different percentage substitutions of hydrogen (0–80% by volume with an increment of 20%) under variable compression ratio conditions (i.e. 7:1, 9:1 and 11:1) by varying the spark ignition timing at a constant speed of 1500 rpm. The various engine performance parameters studied were brake specific fuel consumption, brake mean effective pressure and brake thermal efficiency. It was found from the present study that for specific ignition timing the brake mean effective pressure and the brake thermal efficiency increases with the increase of hydrogen fraction in ethanol and all hydrogen substitutions showed the maximum increase in brake thermal efficiency and reduction in brake specific fuel consumption value at around 25^° CA advanced ignition timing. The best operating conditions were obtained at a compression ratio of 11:1 and the optimum fuel combination was found to be 60–80% hydrogen substitution to ethanol.     

Analysis and assessment of partial re-liquefaction system for liquefied hydrogen tankers using liquefied natural gas (LNG) and H2 hybrid propulsion

Boil-off gas (BOG) is inevitable on board liquefied hydrogen tankers and must be managed effectively, by using it as fuel, re-liquefying it or burning it, to avoid cargo tank pressure issues. This study aims to develop a BOG re-liquefaction system optimized for l60,000 m³ liquefied hydrogen tankers with an LNG and hydrogen hybrid propulsion system. The proposed system comprises hydrogen compression and helium refrigerant sections with 2 J–Brayton cascade cycles. Cold energy recovery from the fuels and feed BOG exiting the cargo tanks was used. The system exhibits a coefficient of performance (COP) of 0.07, a specific energy consumption (SEC) of 3.30 kWh/kg_LH2, and exergy efficiency of 74.9%, with the hydrogen BOG entering the re-liquefaction system at a feed temperature of −220 °C. The theoretical COP and SEC values at ideal conditions were 0.09 and 2.47 kWh/kg_LH2, respectively. The effects of varying the hydrogen compression pressure, inlet temperature of the hydrogen expander, feed hydrogen temperature and helium compression pressure were investigated. Additionally, the LNG-to-hydrogen fuel ratio was adjusted to satisfy the Energy Efficiency Design Index (EEDI) Phase 2 and 3 emission requirements.     

Dissecting the exergy balance of a hydrogen liquefier: Analysis of a scaled-up claude hydrogen liquefier with mixed refrigerant pre-cooling

For liquid hydrogen (LH₂) to become an energy carrier in energy commodity markets at scales comparable to for instance LNG, liquefier capacities must be scaled up several orders of magnitude. While state-of-the-art liquefiers can provide specific power requirements down to 10 kWh/kg, a long-term target for scaled-up liquefier trains is 6 kWh/kg. High capacity will shift the cost weighting more towards operational expenditures, which motivates for measures to improve the efficiency. Detailed exergy analysis is the best means for gaining a clear understanding of all losses occurring in the liquefaction process. This work analyses in detail a hydrogen liquefier that is likely to be realisable without intermediate demonstration phases, and all irreversibilities are decomposed to the component level. The overall aim is to identify the most promising routes for improving the process. The overall power requirement is found to be 7.09 kWh/kg, with stand-alone exergy efficiencies of the mixed-refrigerant pre-cooling cycle and the cryogenic hydrogen Claude cycle of 42.5% and 38.4%, respectively. About 90% of the irreversibilities are attributed to the Claude cycle while the remainder is caused by pre-cooling to 114 K. For a component group subdivision, the main contributions to irreversibilities are hydrogen compression and intercooling (39%), cryogenic heat exchangers (21%), hydrogen turbine brakes (15%) and hydrogen turbines (13%). Efficiency improvement measures become increasingly attractive with scale in general, and several options exist. An effective modification is to recover shaft power from the cryogenic turbines. 80% shaft-to-shaft power recovery will reduce the power requirement to 6.57 kWh/kg. Another potent modification is to replace the single mixed refrigerant pre-cooling cycle with a more advanced mixed-refrigerant cascade cycle. For substantial scaling-up in the long term, promising solutions can be cryogenic refrigeration cycles with refrigerant mixtures of helium/neon/hydrogen, enabling the use of efficient and well scalable centrifugal compressors.     

Power-to-liquid hydrogen: Exergy-based evaluation of a large-scale system

Hydrogen as an energy vector is seen as a key for the energy transition. Recently, more than 30 countries have launched their hydrogen strategies and roadmaps. Hydrogen storage and transportation are challenging steps of the hydrogen economy since all available options have significant drawbacks. This paper evaluates a power-to-liquid hydrogen process; the system is “charged” with electricity from renewable sources to produce hydrogen via water electrolysis; the produced hydrogen gas is liquefied and stored at ambient pressure and cryogenic temperature. The purpose of this paper is to report the first evaluation results of a system including a polymer electrolyte membrane electrolyser and a hydrogen liquefier. The evaluation was conducted using exergy-based methods, i.e. exergetic, exergoeconomic and exergoenvironmental analyses. The process of hydrogen liquefaction was simulated with the aid of the Aspen Plus software. The exergetic efficiencies for the liquefaction process and for the electrolyser are 42% and 47%, respectively. While the total exergetic efficiency of the power-to-liquid hydrogen system amounts to 44%. The total exergy destruction for the liquefier amounts to 9.3 MW and for the polymer electrolyser membrane electrolyser amounts to 19.3 MW. The electrolyser followed by the hydrogen compressors were identified as the components with the highest exergy destruction values and investment costs, while the compressors and the recuperators account for the highest exergoenvironmental impact. The sensitivity analysis shows that the specific liquefaction cost of hydrogen strongly varies with the electricity price and the cost of green hydrogen.     

Analysis and assessment of a novel hydrogen liquefaction process

In the present study, a novel supercritical hydrogen liquefaction process based on helium cooled hydrogen liquefaction cycles to produce liquid hydrogen is thermodynamically analyzed and assessed. The exergy analysis approach is used to study the exergy destruction rates in each component and the process efficiency. The energy and exergy efficiencies of liquefaction process are found to be 70.12% and 57.13%, respectively. In addition, to investigate the process efficiency more comprehensively to see how it is affected by varying process parameters and operating conditions, some parametric studies are undertaken to examine the impacts of different design variables on the energy efficiency, exergy efficiency and exergy destruction rates of the hydrogen liquefaction process. The results show that the increases in the cycle pressure of hydrogen and helium result in increasing hydrogen liquefaction process exergy efficiency and providing a smaller pinch point temperature difference of catalyst beds related with the heat transfer surface area and more efficiently process.     

Comparison criteria for large-scale hydrogen liquefaction processes

In a hydrogen liquefier the pre-compression of feed gas has generally higher stand-alone exergy efficiency than the cooling and liquefaction sub-process. Direct comparison of liquefiers based on overall exergy efficiency and specific power consumption will favour those with a higher portion of pre-compression. A methodology for comparing hydrogen liquefaction processes that compensates for non-uniformity in feed specifications has been developed and applied to three different hydrogen liquefiers. The processes in consideration have been modified to have equal hydrogen feed pressure, resulting in a more consistent comparison. Decreased feed pressure results in generally higher power consumption but also higher exergy efficiency, and vice versa. This approach can be adapted to the boundary conditions that the liquefaction process will be subject to in a real energy system.     

Design of a boil-off natural gas reliquefaction control system for LNG carriers

Onboard boil-off gas (BOG) reliquefaction is a new technology that liquefies BOG and returns it to the cargo tanks instead of burning it off during a voyage. For the commercial development of this technology, an object-oriented dynamic simulation is presented which facilitates the design of the plant and control system for the thermal process. A reliquefaction process based on the reverse Brayton cycle has been designed, and its static thermodynamic states at the design BOG load are presented. To make the cycle work for any BOG load, an idea was sought that would achieve a heat balance with the work extracted by the expander. Dynamic simulations were conducted for all operating modes, including start-up and idle. It was found that the expander exit temperature is the key process variable for control and that the process control works successfully when three actuators are activated in three different BOG load regimes. The study also shows that control of the separator pressure to keep the vapor fraction at the throttle valve exit as low as possible is an efficient method for purging nitrogen from BOG.     

Influence of high compression ratio and hydrogen addition on the performance and emissions of a lean burn spark ignition engine fueled by ethanol-gasoline

This paper investigates the effect of ethanol-gasoline-hydrogen in a lean-burn SI engine with different proportions such as E5, E10, E20, E30, and E40 at compression ratio 10.5:1. The results infer that the E10 blend is the optimized one. Further, E10 mixture investigates for 5% and 10% hydrogen addition on energy basis. Overall, this study establishes that the addition of ethanol enhances brake power by 9% and brake thermal efficiency by about 7%. Hydrogen enrichment to E10 mixture shows a significant enhancement in brake power and brake thermal efficiency at a lower equivalence ratio. Further, it observes that the lean limit had extended to a 0.47 equivalence ratio compared to a 0.5 equivalence ratio with the E10, and 0.54 with pure gasoline. The addition of hydrogen to E10, improves the combustion process and heat release rate while it reduces cycle-by-cycle variations and hydrocarbon emissions.     

Investigations on the effects of intake temperature and charge dilution in a hydrogen fueled HCCI engine

This work was aimed at improving the performance and extending the load range of hydrogen fueled homogeneous charge compression ignition (HCCI) engine through charge temperature regulation and addition of carbon dioxide in order to control the combustion phasing. Intake charge temperature and equivalence ratio were varied from 130 °C to 80 °C and 0.19 to 0.3 respectively. In the neat hydrogen mode it was possible to operate the engine only until a brake mean effective pressure (BMEP) of 2.2 bar. Higher charge temperatures lead to knocking and advanced combustion. At any equivalence ratio the lowest possible charge temperature is the one that leads to the highest thermal efficiency. Addition of carbon dioxide retarded the combustion process and improved the thermal efficiency and also extended the load range to a BMEP of 3.1 bar. Efficiencies of hydrogen HCCI mode were higher than the conventional diesel mode with negligible level of NO emissions.     

Development of a double acting free piston expander for power recovery in transcritical CO2 cycle

To replace the throttling valve with an expander is considered as an efficient method to improve the performance of the transcritical CO₂ refrigeration cycle. This paper presents the design and experimental validation of a double acting free piston expander, in which a slider-based inlet/outlet control scheme is used to realize a full expansion process for the expander. The power extracted from the expansion process is utilized by an auxiliary compressor, which is arranged in parallel with the main compressor. A design model is developed to determine the geometric parameters of the expander together with the auxiliary compressor. An expander prototype is manufactured and validated experimentally in the air test system, mainly by means of analyzing the dynamic pressures in the expander chamber. The experimental results show that the expander can work stably in a wide range of pressure differences/ratios at the frequency approximately linear with the pressure difference through the expander. The p–t diagrams in the expander indicate that the slider-based inlet/outlet control scheme enables the expander to have the proper suction, expansion and discharge processes. However, the prototype at high frequency doesn’t present isobaric suction process, which results in insufficient gas suction and therefore decrease in the expander efficiency. With the p–t diagrams at various frequencies compared, the optimal working frequency is found to range from 10 to 17 Hz in the air system. The isentropic efficiency of 62% is obtained from the p–V diagram analysis. Further validation of the expander in the CO₂ system will be conducted in the near future.     

Small-scale hydrogen liquefaction with a two-stage Gifford–McMahon cycle refrigerator

We manufactured a small-scale hydrogen liquefier with a two-stage 10 K Gifford–McMahon cycle (GM) refrigerator. It had a hydrogen tank with the volume of 30 L that was surrounded by a radiation shield. This liquefier continuously liquefied gaseous hydrogen with the volumetric flow rate of 12.1 NL/min. It corresponds to the liquefaction rate of 19.9 L/day for liquid hydrogen. We proposed a simple estimation method for the liquefaction rate and confirmed that the estimation method well explained the experimental result. To evaluate the estimation method, we applied the estimation method to other liquefiers. In case of a liquefier with the GM refrigerator, we confirmed the estimation method was available for predicting the liquefaction rate. However, in case of a liquefier with the pulse tube refrigerator, the results of the estimation indicated small values as compared with the experimental data. We discuss the details about the estimation method of the liquefaction rate for the small-scale liquefiers.     

Unsteady flows of a scroll expander under various types of expansion process

本工作采用计算流体力学（CFD）的方法对适应于微型压缩空气储能（micro-CAES）系统的涡旋膨胀机工作过程进行非定常数值模拟,得到膨胀机内部压力场、速度场和温度场的分布,研究了相同排气背压下外膨胀比对涡旋膨胀机非稳态性能的影响规律及工作腔流场结构分布,结果显示：排气背压一定时,外膨胀比的变化对进气质量流量的脉动规律影响较小,外膨胀比的增加,增大了出口质量流量脉动程度、增大了膨胀机内压缩空气的热量利用程度、增大了膨胀机非稳态驱动力矩、增大了背压腔内二次流旋涡的强度和尺度,背压腔中存在明显局部高温区。     

氦气离心压气机高压比设计研究

氦气离心压气机是预冷发动机氦回路的核心部件,但国内对氦气离心压气机的相关探究较少。为探究氦气离心压气机的压比设计方法,从离心压气机进口和出口速度三角形的角度,分析了出口安装角、滑移因子以及进气负预旋对叶轮做功的影响。提出了基于低出口安装角、高滑移因子和进气负预旋的高压比设计方法。根据此方法设计出了总压比为2.521、等熵效率为83.2%、喘振裕度为18.55%的氦气离心压气机,并通过数值模拟的方法对此压气机的气动特性以及流场进行了分析,证明了高压比设计方法的可行性。     

Assessment of a synergistic control of intake and exhaust VVT for airflow exchange,combustion, and emissions in a DI hydrogen engine

Variable valve timing (VVT) and Miller cycle are advanced technologies employed to optimize engine performance by improving airflow exchange, which are seldom investigated based on the direct-injection (DI) hydrogen engine. The objective of this study is to assess the effects of intake valve closing (IVC) and exhaust valve opening (EVO) timing on the gas exchange performance, combustion, and emissions of a DI hydrogen engine, after which a synergistic control strategy of IVC and EVO timing is proposed. This work is conducted under wide-open throttle and 1500 rpm. The results indicate that the synergistic control of IVC and EVO timing can increase volumetric efficiency by more than 40%, enhance gas exchange performance, shorten combustion duration, and reduce cyclic variation, resulting in approximately 43.15% brake thermal efficiency. Furthermore, brake mean effective pressure can be increased by more than 60% and NO emissions are controlled to less than 20 ppm by optimizing valve timings.     

Natural gas exergy recovery powering distributed hydrogen production

Natural gas transmission systems often involve a pressure reduction process that does not make use of the mechanical exergy available in the gas. A moderate fraction of this work potential can be extracted using turbo-machinery. This paper quantifies the energy that can be extracted from various pressure reduction facilities using an expander coupled to an electric generator. Produced electricity can either be routed back into the electric distribution grid or used to produce small amounts of hydrogen. A problem with this process is the variable nature of the gas flow rate entering the facility. For the pressure reduction station data used in this study, the gas flow rate may drop to below one quarter of the peak, reducing the efficiency and production rates of the coupled components. A model has been created to analyze these seasonal variations and to produce generalized functions that allow the hydrogen production potential of any pressure reduction facility to be approximated. If the coupled technologies operate at their assumed peak efficiencies, then electricity can be extracted from the pressure reduction with 75% exergetic efficiency and hydrogen can be produced with 45% exergetic efficiency.