Optimization of heat exchanger designs in metal hydride based hydrogen storage systems

Design of the heat exchanger in a metal hydride based hydrogen storage system influences the storage capacity, gravimetric hydrogen storage density, and refueling time for automotive on-board hydrogen storage systems. The choice of a storage bed design incorporating the heat exchanger and the corresponding geometrical design parameters is not obvious. A systematic study is presented to optimize the heat exchanger design using computational fluid dynamics (CFD) modeling. Three different shell and tube heat exchanger designs are chosen. In the first design, metal hydride is present in the shell and heat transfer fluid flows through straight parallel cooling tubes placed inside the bed. The cooling tubes are interconnected by conducting fins. In the second design, heat transfer fluid flows through helical tubes in the bed. The helical tube design permits use of a specific maximum distance between the metal hydride and the coolant for removing heat during refueling. In the third design, the metal hydride is present in the tubes and the fluid flows through the shell. An automated tool is generated using COMSOL-MATLAB integration to arrive at the optimal geometric parameters for each design type. Using sodium alanate as the reference storage material, the relative merits of each design are analyzed and a comparison of the gravimetric and volumetric hydrogen storage densities for the three designs is presented.     

Thermal modeling of LmNi4.91Sn0.15 based solid state hydrogen storage device with embedded cooling tubes

A 2-D mathematical model is developed for predicting the minimum charging/discharging time of the metal hydride based hydrogen storage device by varying the number of cooling tubes embedded in it. This study is extended to 3-D mathematical model for predicting the hydriding and dehydriding characteristics of LmNi_4.91Sn_0.15 based hydrogen storage device with 60 embedded cooling tubes (ECT) using COMSOL Multiphysics 4.3. The performance of the hydrogen storage device during hydriding/dehydriding process is presented for different supply pressure (10–35 bar), hot fluid temperature (30–60 °C) and effective thermal conductivity of hydride bed (0.2–2.5 W/(m?K)). It is observed that the rate of heat transfer and the hydriding and dehydriding rates are enhanced when the number of ECT is increased from 24 to 70. For the reactor with 60 ECT, the rate of hydrogen absorption is rapid for the supply pressure of 35 bar and hydride bed effective thermal conductivity of 2.5 W/(m?K). The numerically predicted hydrogen storage capacity (wt%) and amount of hydrogen desorbed (wt%) are compared with experimental data and found a good accord between them.     

Finite element-based simulation of a metal hydride-based hydrogen storage tank

In this paper, a novel 3D flexible tool for simulation of metal hydrides-based (LaNi₅) hydrogen storage tanks is presented. The model is Finite Element-Based and considers coupled heat and mass transfer resistance through a non-uniform pressure and temperature metal hydride reactor. The governing equations were implemented and solved using the COMSOL Multiphysics simulation environment. A cylindrical reactor with different cooling system designs was simulated. The shortest reactor fill time (15 min) was obtained for a cooling design configuration consisting of twelve inner cooling tubes and an external cooling jacket. Additional simulations demonstrated that an increase of the hydride thermal conductivity can further improve the reactor dynamic performance, provided that the absorbent bed is sufficiently permeable to hydrogen.     

Thermal modeling and performance analysis of industrial-scale metal hydride based hydrogen storage container

In this paper, a performance analysis of a metal hydride based hydrogen storage container with embedded cooling tubes during absorption of hydrogen is presented. A 2-D mathematical model in cylindrical coordinates is developed using the commercial software COMSOL Multiphysics 4.2. Numerical results obtained are found in good agreement with experimental data available in the literature. Different container geometries, depending upon the number and arrangement of cooling tubes inside the hydride bed, are considered to obtain an optimum geometry. For this optimum geometry, the effects of various operating parameters viz. supply pressure, cooling fluid temperature and overall heat transfer coefficient on the hydriding characteristics of MmNi_4.6Al_0.4 are presented. Industrial-scale hydrogen storage container with the capacity of about 150 kg of alloy mass is also modeled. In summary, this paper demonstrates the modeling and the selection of optimum geometry of a metal hydride based hydrogen storage container (MHHSC) based on minimum absorption time and easy manufacturing aspects.     

Thermal–fluid behavior of the hydriding and dehydriding processes in a metal hydride hydrogen storage canister

A study of the hydrogen absorption and desorption processes using LaNi₅ metal hydride is presented for investigation on the influences of expansion volume and heat convection. The hydrogen storage canister comprises a cylindrical metal bed and a void of expansion volume atop the metal. The expansion volume is considered as a domain of pure hydrogen gas. The gas motion in the metal hydride bed is treated as porous medium flow. Concepts of mass and energy conservation are incorporated in the model to depict the thermally coupled hydrogen absorption and desorption reactions. Simulation results show the expansion volume reduces the reaction rates by increasing thermal resistance to the heat transfer from the outside cooling/heating bath. The assumption usually adopted in simulating heat transfer in a metal hydride tank that heat convection in the reaction bed may be ignored is not valid when expansion volume is used because heat convection dominates the heat transfer through the expansion volume as well as the metal bed. The details of the thermal flow pattern are demonstrated. It is found that, due to the action of thermal buoyancy, circulations are likely to happen in the expansion volume. The hydrogen gas accordingly, instead of going directly between the inlet/outlet and the metal bed, tends to move with the circulation along the boundary of the expansion volume.     

Performance prediction of a coupled metal hydride based thermal energy storage system

The present study discusses the thermodynamic compatibility criteria for the selection of metal hydride pairs for the application in coupled metal hydride based thermal energy storage systems. These are closed systems comprising of two metal hydride beds – a primary bed for energy storage and a secondary bed for hydrogen storage. The performance of a coupled system is analyzed considering Mg₂Ni material for energy storage and LaNi₅ material for hydrogen storage. A 3-D model is developed and simulated using COMSOL Multiphysics® at charging and discharging temperatures of 300 °C and 230 °C, respectively. The LaNi₅ bed used for hydrogen storage is operated close to ambient temperature of 25 °C. The results of the first three consecutive cycles are presented. The thermal storage system achieved a volumetric energy storage density of 156 kWh m⁻³ at energy storage efficiency of 89.4% during third cycle.     

Design and investigation of hydriding alloy based hydrogen storage reactor integrated with a pin fin tube heat exchanger

The reaction between metal hydride (MH) and hydrogen gas generates substantial amount of heat. It must be removed rapidly to sustain the reaction in the metal hydride hydrogen storage reactor. Previous studies indicate that the performance of the reactor can be improved by inserting an efficient heat exchanger design inside the metal hydride bed. In the present study, a cylindrical shaped metal hydride system containing LaNi₅, integrated with a finned tube heat exchanger assembly made of copper pin fins and tubes, is presented. A 3-D numerical model is formulated in COMSOL Multiphysics 4.4 to study the transient behavior of sorption process inside the reactor. Experimental data obtained from the literature is used to approve the legitimacy of the proposed model. Influence of various operating and geometric parameters on the total absorption time of the reactor has been investigated. It is found that hydrogen supply pressure is the most influencing factor to increase the absorption rate of hydrogen. Total absorption time of the reactor is found to be 636 s with maximum storage capacity of 1.4 wt% at the operating conditions of 15 bar H₂ gas supply pressure, heat transfer fluid temperature of 298 K and flow rate of 6.75 l/min.     

Discharge dynamics of coupled fuel cell and metal hydride hydrogen storage bed for small wind hybrid systems

In small hybrid wind systems, excess wind energy is stored for later use during the deficit power generation. Excess wind energy can be stored as hydrogen in a metal hydride storage bed and reused later to generate power using a fuel cell. This paper deals with the discharge dynamics of the coupled fuel cell and metal hydride storage bed during the power extraction. Thermal coupling of the fuel cell and metal hydride bed is also discussed. The waste heat generated in the fuel cell is removed using a water coolant. The exit fuel cell coolant stream is passed through the metal hydride storage bed to supply the necessary heat required for desorption of hydrogen from the bed. This will also lead to a reduction in the load on the radiator. The discharge dynamics and the thermal management of the coupled system are demonstrated through a system simulation model developed in Matlab/Simulink platform.     

Performance simulation of metal hydride hydrogen storage device with embedded filters and heat exchanger tubes

A practical metal hydride based hydrogen storage device would consist of many filters to distribute hydrogen gas and heat exchanger tubes to cool or heat the hydride bed depending on whether hydrogen is being absorbed or desorbed. This paper presents the simulation of such a device with LaNi₅ as the hydriding alloy. A study of the geometric and operating parameters has been carried out to identify their influence in the hydriding performance of the storage device.     

Sensitivity study of alanate hydride storage system

A successful metal hydride application is closely related to an optimized design of the storage hydrogen system. In previous studies, Hardy and Anton developed scoping and numerical models describing phenomena occurring during the loading process in an alanate storage system having the configuration of a cylindrical shell, tube and fin heat exchanger. In this paper, the numerical tool is used to evaluate the influence of varying the fin thickness and the number of heat exchanger tubes on both the loading and discharging processes. The objective is to evaluate the influence of the geometric parameters of these heat exchangers on the management of heat to be removed/supplied during the sorption process and thus optimize the loading/discharging times; while having the maximum possible volume for containing the hydride and the lightest weight of the storage system. Results showed that equipping the storage system with fins fitted to the heat exchanger tubes is the best design for efficient use of the hydride bed. In the absence of fins, a number of optimal tubes is determined, however, the hydrogen uptake rate is still lower than one obtained for the finned case and there is a reduction of volumetric and gravimetric storage capacities by comparison to the finned system.     

Thermal Modeling of Mg2Ni-Based Solid-State Hydrogen Storage Reactor

In this paper, a numerical study of coupled heat and hydrogen transfer characteristics in an annular cylindrical hydrogen storage reactor filled with Mg₂Ni is presented. An unsteady, two-dimensional (2-D) mathematical model of a metal hydride reaction bed of cylindrical configuration is developed for predicting the hydrogen storage capacity. The effect of volumetric radiation is accounted in the thermal model. Effects of hydride bed thickness, initial absorption temperature, hydride bed thermal conductivity, and hydrogen supply pressure on the hydrogen storage capacity are studied. A thinner hydride bed is found to enhance the hydriding rate, accomplishing a rapid reaction. At an operating condition of 20 bar supply pressure and 573 K initial absorption temperature, Mg₂Ni stores about 36.7 g hydrogen per kg alloy. For a given bed thickness and an overall heat transfer coefficient, there exists an optimum value of hydride bed thermal conductivity. The present numerical results are compared with the experimental data reported in the literature, and good agreement was observed.     

Using metal hydride H2 storage in mobile fuel cell equipment: Design and predicted performance of a metal hydride fuel cell mobile light

This study examines the practical prospects and benefits for using interstitial metal hydride hydrogen storage in “unsupported” fuel cell mobile construction equipment and aviation GSE applications. An engineering design and performance study is reported of a fuel cell mobile light tower that incorporates a 5 kW Altergy Systems fuel cell, Grote Trilliant LED lighting and storage of hydrogen in the Ovonic interstitial metal hydride alloy OV679. The metal hydride hydrogen light tower (mhH₂LT) system is compared directly to its analog employing high-pressure hydrogen storage (H₂LT) and to a comparable diesel-fueled light tower with regard to size, performance, delivered energy density and emissions. Our analysis indicates that the 5 kW proton-exchange-membrane (PEM) fuel cell provides sufficient waste heat to supply the desorption enthalpy needed for the hydride material to release the required hydrogen. Hydrogen refueling of the mhH₂LT is possible even without external sources of cooling water by making use of thermal management hardware already installed on the PEM fuel cell. In such “unsupported” cases, refueling times of ∼3–8 h can be achieved, depending on the temperature of the ambient air. Shorter refueling times (∼20 min) are possible if an external source of chilled water is available for metal hydride bed cooling during rapid hydrogen refueling. Overall, the analysis shows that it is technically feasible and in some aspects beneficial to use metal hydride hydrogen storage in portable fuel cell mobile lighting equipment deployed in remote areas. The cost of the metal hydride storage technology needs to be reduced if it is to be commercially viable in the replacement of common construction equipment or mobile generators with fuel cells.     

Entropy generation and its relation to heating and cooling requirements of a metal hydride hydrogen storage reactor

In this paper a metal hydride hydrogen storage reactor is analyzed from heat and mass transfer and entropy generation points of view. A transient two dimensional energy equation along with suitable reaction kinetics and entropy balance equation is solved numerically. Results are obtained keeping hydrogen flow rates constant during absorption and desorption. For a fixed mass of metal hydride in the reactor the amount of hydrogen transferred and the time in which the transfer takes place are kept fixed. Using the mathematical model the entropy generated during the process and the external cooling and heating fluid requirements are obtained. Results show how improvement in the design and/or operating conditions leads to reduced cooling and heating requirements and lower entropy generation. For the system considered in the study the internal heat transfer characteristics of the hydride bed are seen to influence the reactor performance significantly. With improved bed heat transfer the required heat transfer fluid temperature during desorption can be reduced and that during absorption can be increased significantly. This automatically leads to lower entropy generation and a more economic system operation. It is expected that the methodology proposed and the results presented in this study will be useful in the optimal design of metal hydride reactors for a variety of practical applications, including hydrogen storage.     

Predicting hydrogen adsorption and desorption rates in cylindrical metal hydride beds: Empirical correlations and machine learning

A major limitation in chemisorptive hydrogen storage in metal hydrides is the long time required for the adsorption reaction during charging. This study investigates how the shape and material of the reaction chamber influences the adsorption and desorption rates. Numerical simulations of hydrogen storage in a cylindrical reaction chamber filled with LaNi₅ hydride are conducted for a range of chamber thermal conductivities and aspect ratios. The results show that adsorption and desorption processes are limited by thermal diffusion in the hydride bed and storage chamber. A storage efficiency is proposed based on an ideal isothermal process and used to evaluate the impact of chamber thermal conductivity and aspect ratio on the adsorption and desorption rates. Empirical correlations are proposed for predicting the adsorption and desorption efficiency of cylindrical LaNi₅ hydride beds. Finally, a machine-learning based data model for predicting storage efficiency in metal hydride chambers is presented. Comparison against the empirical correlations highlights that the machine learning-based data model can predict the storage efficiency more accurately.     

Heat transfer characteristics of the metal hydride vessel based on the plate-fin type heat exchanger

Heat transfer characteristics of the metal hydride vessel based on the plate-fin type heat exchanger were investigated. Metal hydride beds were filled with AB₂ type hydrogen-storage alloy’s particles, Ti_0.42Zr_0.58Cr_0.78Fe_0.57Ni_0.2Mn_0.39Cu_0.03, with a storage capacity of 0.92 wt.%. Heat transfer model in the metal hydride bed based on the heat transfer mechanism for packed bed proposed by Kunii and co-workers is presented. The time-dependent hydrogen absorption/desorption rate and pressure in the metal hydride vessel calculated by the model were compared with the experimental results. During the hydriding, calculated hydrogen absorption rates agreed with measured ones. Calculated thermal equilibrium hydrogen pressures were slightly lower than the measured hydrogen pressures at the inlet of metal hydride vessel. Taking account of the pressure gradient between the inlet of metal hydride vessel and the metal hydride bed, it is considered that this discrepancy is reasonable. During the dehydriding, there were big differences between the calculated hydrogen desorption rates and measured ones. As calculated hydrogen desorption rates were lower than measured ones, there were big differences between the calculated thermal equilibrium hydrogen pressures and the measured hydrogen pressures at the inlet of metal hydride vessel. It is considered that those differences are due to the differences of the heat transfer characteristics such as thermal conductivity of metal hydride particles and porosity between the assumed and actual ones. It is important to obtain the heat transfer characteristics such as thermal conductivity of metal hydride particles and porosity both during the hydriding and dehydriding to design a metal hydride vessel.     

Experiments on solid state hydrogen storage device with a finned tube heat exchanger

The absorption and desorption performances of a solid state (metal hydride) hydrogen storage device with a finned tube heat exchanger are experimentally investigated. The heat exchanger design consists of two “U” shaped cooling tubes and perforated annular copper fins. Copper flakes are also inserted in between the fins to increase the overall effective thermal conductivity of the metal hydride bed. Experiments are performed on the storage device containing 1 kg of hydriding alloy LaNi₅, at various hydrogen supply pressures. Water is used as the heat transfer fluid. The performance of the storage device is investigated for different operating parameters such as hydrogen supply pressure, cooling fluid temperature and heating fluid temperature. The shortest charging time found is 490 s for the absorption capacity of 1.2 wt% at a supply pressure of 15 bar and cooling fluid temperature and velocity of 288 K and 1 m/s respectively. The effect of copper flakes on absorption performance is also investigated and compared with a similar storage device without copper flakes.     

Theory of the computer code RET 1 for the calculation of space-time dependent temperature and composition properties of metal hydride hydrogen storage beds

The work presented is a part of an extensive hydrogen energy research program conducted by the Inshas Nuclear Research Center (Egypt). The physical and mathematical modelling of the metal hydride hydrogen storage beds considered in the RET 1 computer code is described. A cylindrical conduction bed model is used. Two alternatives are considered for heat exchange: either fluid is passing through tubes surrounded by solid alloy, or solid alloy rods surrounded by annular fluid tubes. The numerical solution of the associated mass and heat transfer problem is discussed. In this solution, implicit finite difference approximations derived by Taylor expansions are applied. Some of the numerical results obtained by the RET 1 computer code are interpreted.     

Dynamics of hydrogen powered CAES based gas turbine plant using sodium alanate storage system

Typical compressed air energy storage (CAES) based gas turbine plant operates on natural gas or fuel oils as fuel for its operation. However, the use of hydro-carbon fuels will contribute to carbon emissions leading to pollution of the environment. On the other hand, the use of hydrogen as fuel for the gas turbine will eliminate the carbon emissions leading to a cleaner environment. Hydrogen can be produced using renewable energy sources like wind, solar etc. Storage of hydrogen is a bottleneck for such a system. A high capacity sodium alanate metal hydride bed is used in this study to store the hydrogen. The dynamics of the CAES based gas turbine plant operating with hydrogen fuel is presented along with discharge dynamics of the metal hydride bed. The heat required for desorbing the hydrogen from the metal hydride bed is provided partly by the hot flue gas exiting from the low pressure turbine and partly by external heating. Thus some of the heat from the flue gas is extracted. A novel multiple bed strategy is employed for efficient desorption. Each bed consists of a shell and tube, with alanate in the shell and heating fluid flowing through the helical coiled tube. Hydrogen combustor is modeled using a simplified Continuous Stirred Tank Reactor (CSTR) assumption in CANTERA. The NO_x emissions in the low pressure turbine exhaust stream are presented.     

The comprehensive review for development of heat exchanger configuration design in metal hydride bed

An optimal hydrogen storage reactor should have a higher chemical reaction rate by which the heat can be exchanged as fast as possible. The configuration of heat exchanger structure design plays a crucial role in improving heat and mass transfer effect in metal hydride beds. Consequently, a variety of different metal hydride bed configurations have been investigated in experimental and simulation works for the improvement of absorption/desorption rate. In this work, the development of metal hydride bed design in recent decades has been reviewed to help the readers summarize and optimize the reactor configuration. The summarization and review of metal hydrides design can be broadly classified into five distinct categories, which are: 1) design of cooling tubes, 2) design of fins, 3) increasing and arrangement of cooling tubes, 4) other geometric design, and 5) utilization of phase change material. This work is concentrated on assessing the heat and mass transfer effectiveness of various reactor structure configurations. The superiority and weakness of different configurations are summarized to give a comparison of the heat exchange effects. Moreover, the structural parameter analysis for each configuration is also reviewed from the heat and mass transfer aspect. Finally, some recommendations are provided for future metal hydride bed structural designs.     

Performance analysis of LaNi5 added with expanded natural graphite for hydrogen storage system

This paper presents a comparative study of two cases of metal hydride hydrogen storage units working on (i) LaNi₅ (ii) Compacts of LaNi₅ incorporated with expanded natural graphite (ENG). It has been observed from the previous studies that the hydriding/dehydriding reactions eventually causes large strain changes, due to which the hydride forming metal alloys disintegrate and form a powder bed. Such reactor beds usually have a low thermal conductivity which minimizes the heat transfer phenomenon occurring during the absorption of hydrogen gas. Therefore, there is a need to implement heat augmentation methods to significantly enhance the thermal conductivity. The objective of this research is to present a 2-D numerical model using Finite Volume Method (FVM) and estimate the hydrogen storage performance of a cylindrical metal hydride bed for both the cases, i.e. powdered metal hydride bed and ENG compacts-based reactor bed at different values of inlet pressure and heat transfer fluid temperature. In this study, a detailed investigation on the absorption process reveals that reactor beds with compacted disks of LaNi₅ and ENG demonstrate an enhanced effective thermal conductivity and efficient mass transfer. The simulation results show that a remarkable improvement in the heat transfer and hydrogen storage capacity with reduced absorption time can be achieved by using LaNi₅ and ENG compacts. It was observed that the average reactor bed temperature dropped from 345.13 K to 337.37 K when the ENG based compacted disks was introduced into the reactor bed. Moreover, for supply pressure of 24 bar and fluid temperature of 293 K, the time taken to absorb hydrogen into the rector to achieve stabilized hydrogen storage capacity was estimated to be 446s and 232 s for the case of metal hydride and ENG compacts-based bed, respectively.