Experimental study of a metal hydride vessel based on a finned spiral heat exchanger

The reaction time of hydrogen in metal hydride vessels (MHVs for short) is strongly influenced by the heat transfer from/to the hydride bed. In the present work an experimental study of the geometric and the operating parameters of a finned spiral heat exchanger has been carried out to identify their influence on the performance of the charging process of the MHV. The experimental results show that the charge time of the reactor is considerably reduced, when finned spiral heat exchanger is used. In addition, the effect of different parameters (flow mass and temperature of the cooling fluid, applied pressure, and hydrogen tank volume) has been discussed and obtained results show that a good choice of these parameters is important.     

Effect of design parameters on enhancement of hydrogen charging in metal hydride reactors

The effects of heat transfer mechanisms on the charging process in metal hydride reactors are studied under various charging pressures. Three different cylindrical reactors with the same base dimensions are designed and manufactured. The first one is a closed cylinder cooled with natural convection, the fins are manufactured around the second reactor and the third reactor is cooled with water circulating around the reactor. The temperatures of the reactor at several locations are measured during charging with a range of pressure of 1–10 bar. The third reactor shows the lowest temperature increase with the fastest charging time under all charging pressures investigated. The effective heat transfer coefficients of the reactors are also calculated according to the experimental results and they are found to be 5.5 ± 1 W m⁻² K⁻¹, 35 ± 2 W m⁻² K⁻¹ and 113 ± 1 W m⁻² K⁻¹, respectively. The experimental results showed that the charging of hydride reactors is mainly heat transfer dependent and the reactor with better cooling exhibits the fastest charging characteristics.     

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.     

Optimized heat transfer fin design for a metal-hydride hydrogen storage container

This paper presents a heat transfer fin optimization for a LaNi₅ hydrogen storage container. In this simplified approach, a one-dimension fin model is proposed in order to avoid geometrical restrictions and constrains associated to a particular technological solution. Therefore, the presented model can be utilized as a general framework for the development of containers with inner fins.     

Simulation of transient heat and mass transfer during hydrogen sorption in cylindrical metal hydride beds

A CFD analysis of heat and mass transfer in cylindrical metal hydride beds is carried out using the commercial code Fluent 6.2. The effect of bulk diffusion is considered for mass transfer in the solid phase. Temporal and spatial variations of temperature and concentration in hydride bed are plotted. Emphasis is given to monitor the motion of hydrogen within the bed and to the influence of the L/D$L/D$ ratio and porosity. It is observed that a concentration variation in the bed is the driving force for hydrogen flow in hydride beds. The gas movement is observed to be from saturated cooler peripheral region towards the unsaturated hotter core region of the bed.     

A new algorithm for solving transient heat and mass transfer in metal–hydrogen reactor

A new algorithm based on the lattice Boltzmann method (LBM) is proposed as a potential solver for two-dimensional and dynamic heat and mass transfer in metal–hydrogen reactor. To check the validity of this algorithm, computational results have been compared with the experimental data and a good agreement is obtained. The advantages of the proposed numerical approach include, among others, simple implementation on a computer, accurate CPU time, and capability of stable simulation.     

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.     

Impacts of external heat transfer enhancements on metal hydride storage tanks

The rate at which hydrogen can be drawn from a metal hydride tank is strongly influenced by the rate at which heat can be transferred to the reaction zone. In this work, the impacts of external convection resistance on thermodynamic behaviour inside the metal hydride tank are examined. A one-dimensional resistive analysis and two-dimensional transient model are used to determine the impact of external fins on the ability of a metal hydride tank to deliver hydrogen at a specified flow rate. For the particular metal hydride alloy (LaNi₅) and tank geometry studied, it was found that the fins have a large impact on the pressure of the hydrogen gas within the tank when a periodic hydrogen demand is imposed. Model results suggest that the metal hydride alloy at the centre of the tank can be removed to reduce weight and cost, without detrimental effects to the performance of the system.     

Predictive calculation of the effective thermal conductivity in a metal hydride packed bed

The effective thermal conductivity of a metal hydride packed bed was calculated by considering the influence of expansion during hydrogen absorption and contraction during hydrogen desorption. The porosity was calculated using an experimental formula developed by direct observation, which was used in combination with other referenced methods. However, none of the methods could express the reported experimental value response to pressure change using only the experimental porosity formula. The area contact model was modified so that the porosity and the contact area changed with expansion and contraction. The contact area change was calculated by assuming a simple geometrical deformation caused the difference between the particle expansion and the packed bed expansion. The calculation results of the improved area contact model with the deformed factor and the shape factor were in good agreement with the reported experimental data. This calculation method of the effective thermal conductivity with the influence of expansion and contraction is expected to be useful for designing of heat transfer enhancement of a hydrogen storage tank.     

Improved hydrogen storage properties of Mg-based nanocomposite by addition of LaNi5 nanoparticles

Mg (200 nm) and LaNi₅ (25 nm) nanoparticles were produced by the hydrogen plasma-metal reaction (HPMR) method, respectively. Mg–5 wt.% LaNi₅ nanocomposite was prepared by mixing these nanoparticles ultrasonically. During the hydrogenation/dehydrogenation cycle, Mg–LaNi₅ transformed into Mg–Mg₂Ni–LaH₃ nanocomposite. Mg particles broke into smaller particles of about 80 nm due to the formation of Mg₂Ni. The nanocomposite showed superior hydrogen sorption kinetics. It could absorb 3.5 wt.% H₂ in less than 5 min at 473 K, and the storage capacity was as high as 6.7 wt.% at 673 K. The nanocomposite could release 5.8 wt.% H₂ in less than 10 min at 623 K and 3.0 wt.% H₂ in 16 min at 573 K. The apparent activation energy for hydrogenation was calculated to be 26.3 kJ mol⁻¹. The high sorption kinetics was explained by the nanostructure, catalysis of Mg₂Ni and LaH₃ nanoparticles, and the size reduction effect of Mg₂Ni formation.     

Three-dimensional modeling of hydrogen sorption in metal hydride hydrogen storage beds

This paper conducts a three-dimensional (3D) modeling study to investigate the hydrogen absorption process and associated mass and heat transport in a metal hydride (LaNi₅) hydrogen storage tank. The 3D model is further implemented numerically for validation purpose and the detailed investigation on absorption process. Results indicate that at the very initial absorption stage the bed temperature evolves almost uniformly, while it varies greatly spatially at the latter stage. At the initial seconds, most hydrogen is absorbed in the region near the cooling wall due to the better heat removal. The absorption in the core is slow at the beginning, but becomes important at the very end stage. It also shows that the initial hydrogen flow in the bed is several-fold larger than the latter stage and the flow may provide extra cooling to the hydriding process. By analyzing the Peclet number, we find that the heat convection by the hydrogen flow may play an important role in local heat transfer. This work provides an important platform beneficial to the fundamental understanding of multi-physics coupling phenomena during hydrogen absorption and the development of on-board hydrogen storage technology.     

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.     

Economic potential of complex hydrides compared to conventional hydrogen storage systems

Novel developments of materials for solid hydrogen storage show promising prospects. Complex hydrides exhibit great technical potential to store hydrogen in an efficient and safe way. Nevertheless, so far an evaluation of economic competitiveness is still lacking. In this work, an assessment about the economic feasibility of implementing complex hydrides as hydrogen storage materials is presented. The cost structure of hydrogen storage systems based on NaAlH₄ and LiBH₄/MgH₂ is discussed and compared with the conventional high pressure (700 bar) and liquid storage systems. The vessel construction for the complex hydride systems is much simpler than for the alternative conventional methods because of the milder pressure and temperature conditions during the storage process. According to the economical analysis, this represents the main cost advantage of the complex hydride systems.     

Demonstration of a micro-fabricated hydrogen storage module for micro-power systems

The objective of this work was to demonstrate a micro-fabricated hydrogen storage module for micro-power systems. Hydrogen storage materials were developed as thin-film inks to be compatible with an integrated manufacturing process. Performance and durability of storage modules were evaluated. Further, applications were demonstrated for a nickel-hydrogen battery and a micro-fabricated hydrogen-air PEM fuel cell. The ink making process, in which polymer binders and solvents were added to the palladium-treated alloys, slightly decreased the storage capacities, but had little effect on the activation properties of the treated alloys. After 5000 absorption/desorption cycles under hydrogen, the hydrogen storage capacities of the thin-film inks remained high. Absorption/desorption behavior of the ink was tested in the environment of a new type nickel-hydrogen battery, in which it would in contact with 26 wt% KOH solution, and the ink showed no apparent degradation. Storage modules were successfully used as the hydrogen source for PEM fuel cell.     

Enhancement of hydrogen storage performance in shell and tube metal hydride tank for fuel cell electric forklift

Novel metal hydride (MH) hydrogen storage tanks for fuel cell electric forklifts have been presented in this paper. The tanks comprise a shell side equipped with 6 baffles and a tube side filled with 120 kg AB₅ alloy and 10 copper fins. The alloy manufactured by vacuum induction melting has good hydrogen storage performance, with high storage capacity of 1.6 wt% and low equilibrium pressure of 4 MPa at ambient temperature. Two types of copper fins, including disk fins and corrugated fins, and three kinds of baffles, including segmental baffles, diagonal baffles and hole baffles, were applied to enhance the heat transfer in metal hydride tanks. We used the finite element method to simulate the hydrogen refueling process in MH tanks. It was found that the optimized tank with corrugated fins only took 630 s to reach 1.5 wt% saturation level. The intensification on the tube side of tanks is an effective method to improve hydrogen storage performance. Moreover, the shell side flow field and hydrogen refueling time in MH tanks with different baffles were compared, and the simulated refueling time is in good agreement with the experimental data. The metal hydride tank with diagonal baffles shows the shortest hydrogen refueling time because of the highest velocity of cooling water. Finally, correlations regarding the effect of cooling water flow rate on the refueling time in metal hydride tanks were proposed for future industrial design.     

Charging dynamics of metal hydride hydrogen storage bed for small wind hybrid systems

Small hybrid wind systems are capable of storing and supplying power for residential applications. In this paper, the excess wind energy is converted into hydrogen by electrolysis and is stored in a metal hydride. Metal hydride beds are known for their high volumetric capacity compared to the compressed hydrogen storage, and offers hydrogen storage at a reasonable operating temperature and pressure. A system simulation model is developed in Matlab/Simulink platform for the dynamics of the metal hydride hydrogen storage system, which is charged by the wind energy. The thermal loads of the metal hydride storage system is met by passing water at ambient temperature for cooling the bed while hydrogen is being absorbed. The effect of the transient turbulent wind velocity profile on the storage system is analyzed. The thermal management of the storage system plays an important role in the overall design, and hence it is discussed in detail.     

Experimental studies on LaNi4.25Al0.75 alloy for hydrogen and thermal energy storage applications

Reversible exothermic and endothermic reactions between metals/alloys and hydrogen gas provide great opportunity to utilize various thermal energy sources such as waste heat, industrial exhaust, and solar thermal energy. Metal hydrides with favourable properties to operate at medium temperature heat (about 150 °C) are limited, and studies on hydrides in this temperature range are scarce. Hence, the present study aims at experimental investigations on LaNi_4.25Al_0.75 alloy in the temperature range of 150 °C–200 °C. A novel cartridge type of reactor is employed to investigate the hydrogen storage characteristics and thermal storage performance of this alloy. LaNi_4.25Al_0.75 is found to have a hydrogen storage capacity of about 1.20 wt% at 10 bar and 25 °C. In addition, it can store a total thermal energy of 285.7 ${\mathrm{k}\mathrm{J}.\mathrm{k}\mathrm{g}}_{\mathrm{M}\mathrm{H}}^{-1}$ and can deliver heat at an average rate of 287.5 ${\mathrm{W}.\mathrm{k}\mathrm{g}}_{\mathrm{M}\mathrm{H}}^{-1}$ at an efficiency of 64.1%.     

Experimental formula for estimating porosity in a metal hydride packed bed

An experimental formula for estimating porosity in a metal hydride packed bed is presented. The formula was developed by direct observation of the volume changes of a metal hydride packed bed under free expansion in a vessel. The experimental results showed that the cycles of expansion and contraction were repeated at large porosities above 60% after a rapid state change caused by early particle breakup. The formula for porosity was expressed as a function of the reacted fraction and as a function of the cycle number. The function formula of the reacted fraction can be used to compute different values of porosity for expansion by absorption and for contraction by desorption. The coefficients assuming 100% hydrogen storage based on the experiments with LaNi₅ were an expansion ratio of 16.7% and a contraction ratio of 8.4%, on average. This experimental porosity formula is useful for effective thermal conductivity calculations and for numerical simulations of metal hydride packed bed behavior.