Pressure analysis on two-step high pressure reducing system for hydrogen fuel cell electric vehicle

Hydrogen fuel cell electric vehicle (FCEV) can achieve zero exhaust emission and zero pollution. In order to make FCEV reach a farther travel distance, greater demands are put on its pressure reducing system. In this paper, a two-step high pressure reducing system for FCEV is proposed. The system is made up of two parts, a new high multi-stage pressure reducing valve (HMSPRV) and a multi-stage muffler. As a new system, its feasibility has to be verified. Since the valve opening condition has a great effect on hydrogen flow, pressure reduction and energy consumption, different valve opening conditions are taken as the research point. The flow field analysis of the new HMSPRV is conducted on three aspects: pressure field, velocity field and energy consumption. It can be found that both the pressure reducing and velocity increasing gradients mainly reflect at those throttling components for all valve openings. For energy consumption, in the comprehensive study of flow vortexes and turbulent dissipation rate, it can be found that the larger of the valve opening, the larger of energy consumption. Then, a thermo-fluid-solid coupling analysis is conducted on the new HMSPRV, and it is concluded that the new system meets strength requirement. Furthermore, as the second step of the high pressure reducing system, the flow and pressure fields of multi-stage muffler are investigated. The five-stage muffler is exactly designed to complete the whole pressure reducing process. This study can provide technological support for achieving pressure regulation in the hydrogen transport system of FCEV when facing complex conditions, and it can also benefit the further research work on energy saving and multi-stage flow of pressure reducing devices.     

Co-design and aerodynamic study on a two-step high pressure reducing system for hydrogen decompression: From hydrogen refueling station to hydrogen fuel cell vehicle

Fuel for hydrogen fuel cell vehicles comes from hydrogen refueling stations. During the hydrogen filling process, a high-pressure gradient from 35 MPa (hydrogen storage pressure) to 0.16 MPa (fuel cell pressure) is generated. Such a large pressure gradient posed a challenge to the design of the pressure reducing system. Traditional system is difficult to reduce hydrogen pressure from 35 MPa to 0.16 MPa without accompanying large noise and energy consumption. This work is exploring a new concept to combine the multi-stage continuous resistance perforated components and the Tesla valve to design a two-step high pressure reducing system for hydrogen decompression. To validate the superiority of the developed system, a detailed aerodynamic study on the new system is performed, since aerodynamic performance directly affects the operating flexibility and stability. Finally, the optimized co-design of the system is achieved. Results show that the new system is well-designed for hydrogen decompression with the function of control noise and energy consumption. Larger orifice radius (r₁/r₀) and orifice ratio (k) contribute the better aerodynamic performance. Angle α = 45° is considered the best for better aerodynamic performance. The descending order of the effects on better aerodynamic performance is angle (α), row (m), sleeve stage (N), orifice radius (r₁/r₀) and width (t₁/t₀). This study provides basic support for experts to achieve throttling design of related pressure control systems in hydrogen industry.     

Parametric study on Tesla valve with reverse flow for hydrogen decompression

Recharge mileage is of great importance for a hydrogen fuel cell electric vehicle. High pressure hydrogen storage can increase the recharge mileage significantly. Before hydrogen flows into the fuel cell, a decompression process is necessary. To overcome the seal of the piping system and realize the decompression, Tesla valve can be well used, since it is a type of check valve without moving parts, and when there is a reverse flow, large pressure drop appears between the inlet and outlet. In order to obtain a better pressure drop performance for a Tesla valve, in this paper, the structural parameters including the hydraulic diameter, the valve angle, and the inner curve radius are investigated for a large range of inlet velocities. The results indicate that a small hydraulic diameter and small inner curve radius but large valve angle can provide a higher pressure drop under a large inlet velocity, while the pressure drop under different structural parameters barely changes under a small inlet velocity (less than 100 m/s). Besides, there is a low-pressure zone behind the outlet of the bend channel, which should be paid attention. This work can be referred by the further applications of Tesla valves in hydrogen fuel cell electric vehicles for hydrogen decompression.     

Thermodynamic modeling of hydrogen fueling process from high-pressure storage tank to vehicle tank

This study develops a hydrogen fueling station (HFS) thermodynamic model that simulates the actual fueling process in which hydrogen is supplied from a high-pressure (HP) storage tank into a fuel cell electric vehicle (FCEV) tank. To make the model as accurate as possible, we use the same components and specifications as in actual HFSs, such as a pressure control valve, a pre-cooling system, and an FCEV tank. After the components and their specifications are set, pressure and temperature profiles are set as the HP tank supply conditions. Based on the pressure and temperature profiles, the model solves for the temperature, pressure, and mass flow rate of hydrogen at each downstream position, including the inside of the vehicle tank. The values predicted by the model are compared with experimental data, and we show that the developed model makes it possible to accurately simulate those values at any position during the fueling process.     

Hydrogen decompression analysis by multi-stage Tesla valves for hydrogen fuel cell

Hydrogen fuel cell is an ideal power source for electric vehicles. For a hydrogen fuel cell electric vehicle, the hydrogen is reserved in a high pressure level to promote the recharge mileage while relatively low-pressure hydrogen is demanded for proper functioning of the fuel cell stack, so that decompression of hydrogen is needed before hydrogen flowing into the fuel cell. With a reverse flow through Tesla valves, there appears a large pressure drop between the inlet and outlet, which can be used for hydrogen decompression nicely. However, a single-stage Tesla valve cannot meet the pressure drop requirement, so multi-stage Tesla valves are utilized. In this paper, numerical simulations of reversed hydrogen flow through multi-stage Tesla valves are carried out. The stage number of multi-stage Tesla valves and the inlet/outlet pressure ratio are both studied, and the distributions of temperature, pressure, and velocity inside multi-stage Tesla valves are all investigated. Results show that as the stage number increases or the inlet/outlet pressure ratio decreases, the pressure and the velocity inside multi-stage Tesla valves decrease, and the less the stage number, the more possibility for the velocity higher than local acoustic speed. Besides, a power-law relationship between the flow rate, the stage number and pressure ratio is summarized.     

Study on the high-pressure hydrogen gas flow characteristics of the needle valve with different spool shapes

The needle valve is a critical control unit for high-pressure hydrogen systems such as hydrogen refueling stations, which is the infrastructure of hydrogen energy. As an important part of the needle valve, the valve spool affects the flow characteristics of hydrogen in the valve and then affects the working performance and safety of the high-pressure hydrogen valve. In this paper, based on the real hydrogen gas model and the finite volume method, a CFD model of the high-pressure hydrogen needle valve is constructed to find out the influence of the valve spool shape on the performance and flow characteristics of the high-pressure hydrogen needle valve. The results show that high-pressure hydrogen will produce a sudden change in pressure around the valve spool and there will be a local high-speed area, and the turbulent intensity will also increase. The arc cone spool can increase the flow by 2%–8% at different openings of the valve, and reduce the maximum speed at the spool by 15% at small openings. In addition, the sudden change of pressure and the eddy current have also been improved. Flat-bottomed cone spool reduces turbulence intensity and energy consumption. Therefore, it can be concluded that changing the shape of the valve spool to have a larger flow area at a small opening can make the high-pressure hydrogen valve have a better flow field distribution. Flattening the cone angle of the spool can improve the turbulent flow in the valve. The research in this paper can provide research accumulation and theoretical support for the optimization design of the needle valve of the high-pressure hydrogen system.     

Generation of high-pressure hydrogen for fuel cell electric vehicles using photovoltaic-powered water electrolysis

Increasing the utilization of electric drive systems including hybrid, battery, and fuel cell electric vehicles (FCEV) will reduce the usage of petroleum and the emission of air pollution by vehicles. The eventual production of electricity and hydrogen in a renewable fashion, such as using solar energy, can achieve the long-term vision of having no tailpipe emissions, as well as eliminating the dependence of the transportation sector on dwindling supplies of petroleum for its energy. Before FCEVs can be introduced in large numbers, a hydrogen-fueling infrastructure is needed. This report describes an early proof-of-concept for a distributed hydrogen fueling option in which renewably generated, high-pressure hydrogen is dispensed at an FCEV owner’s home. In an earlier report we described the design and initial characterization of a solar photovoltaic (PV) powered electrolyzer/storage/dispensing (ESD) system that was a proof-of-concept for a single FCEV home fueling system. In the present report we determined the efficiency and other operational characteristics of that PV-ESD system during testing over a 109-day period at the GM Proving Ground in Milford, MI, at a hydrogen output pressure of approximately 2000 psi (13.8 MPa). The high pressure was achieved without any mechanical compression via electrolysis. Over the study period the photovoltaic solar to electrical efficiency averaged 13.7%, the electrolyzer efficiency averaged 59%, and the system solar to hydrogen efficiency averaged 8.2% based on the hydrogen lower heating value. A well-documented model used to evaluate solar photovoltaic power systems was used to calculate the maximum power point values of the voltage, current, and power of our PV system in order to derive the coupling factor between the PV and ESD systems and to determine its behavior over the range of environmental conditions experienced during the study. The average coupling factor was near unity, indicating that the two systems remained coupled in an optimal fashion. Also, the system operated well over a wide range of meteorological conditions, and in particular it responded quickly to instantaneous changes in the solar irradiance (caused by clouds) with negligible effect on the overall efficiency. During the study up to 0.67 kg of high-pressure hydrogen was generated on a sunny day for fueling FCEV. Future generations of high-pressure electrolyzers, properly combined with solar PV systems, can offer a compact, efficient, and environmentally acceptable system for FCEV home fueling.     

Hydrogen and LNG production from coke oven gas with multi-stage helium expansion refrigeration

Here we propose a novel cryogenic system to simultaneously produce liquid hydrogen (LH₂) and liquefied natural gas (LNG) from coke oven gas. The coke oven gas, simplified as a mixture of methane and hydrogen, directly enters the cryogenic system. Due to the very low temperature of liquid hydrogen, helium is selected as the refrigerant, and the energy needed for the liquefaction is supplied by a multi-stage helium expansion refrigeration system. The high-purity liquid hydrogen and LNG products are obtained with the help of a cryogenic distillation column. The whole cryogenic process is simulated with the Aspen HYSYS software to determine the parameters of each process point and key component. We found that the process is able to produce LH₂ and LNG of very high purity. Using the power consumption of the product liquefaction as the major performance parameter for the analysis, optimum parameters of the multi-stage helium expansion liquefaction process could be found. The results show that the proposed system can achieve a methane recovery rate of 97.9% and a hydrogen recovery rate of 99.7% with acceptable energy consumption.     

EVALUATION OF PERFORATED PLATE SOLAR AIR HEATER

Perforated plates had been successfully used in recent years to achieve high heat transfer coefficient from the absorber plate to the flowing air stream in solar air heaters. Since pumping pressure to maintain a particular flow in the solar air heater utilizing this type of absorber has significant influence on collected energy, so the design of perforated plate configuration must be based on the net energy gained from that collector which is the difference between energy collected and energy paid to overcome pumping pressure. A mathematical model had been constructed and validated experimentally for perforated plate solar air heater to study the effect of plate configurations and airflow rate on both energy gained and pressure loss. The results show that, the flow rate of air and plate configurations have a great effect on net energy gained from the air heater. The results also show that a plate of certain configurations operates most efficiently at certain flow rate and more than one configurations can give optimum value of net energy gained for a particular flow rate.     

Numerical study on the behavior and design of a novel multistage hydrogen pressure-reducing valve

Applying hydrogen fuel-cell vehicles (HFCVs) is feasible to achieve net zero carbon emission in transportation sector. The energy density requirements of these vehicles are fulfilled via high-pressure gaseous hydrogen storage; therefore, an effective pressure-reducing system is necessary. In this work, a novel multistage pressure-reducing valve (named as T–M valve) combining a sleeve pressure structure valve and a Tesla-type orifice valve is proposed. A computational fluid dynamics (CFD) model is developed to analyze the influence of operating parameters on pressure and velocity distributions. Results show that the large pressure and velocity gradients’ region is concentrated on the throttling elements. The valve opening and pressure ratio significantly affect energy consumption. In addition, the Mach number in the valve less than one is proposed. This study is conducive to further energy conservation and emission reduction and the research of multistage flow pressure-reducing devices.     

High efficient separation of H2/CH4 using ZIF-8/glycol-water slurry: Process modelling and multi-objective optimization

Hydrogen (H₂) is expected to play a vital role in future global energy system. The efficient and low-energy consumption process for H₂/CH₄ separation from hydrogen rich industrial off-gas is still a key challenge. The absorption-adsorption process for H₂/CH₄ separation using ZIF-8/glycol-water slurry is a promising alternative technique due to its high separation efficiency, mild operation conditions and continuous operation mode. We proposed two process configurations: a decompression desorption process A to obtain 99.5 mol% H₂; and a process B combined with decompression and H₂ stripping desorption to attain 99.99 mol% H₂. The detailed process modelling and multiple objective optimizations for two processes are conducted to determine optimal operation conditions, stream characteristics, and unit energy requirements. Results show that the H₂ recovery ratio and total unit energy consumption reaches 99.70% and 0.3876 kW·h/Nm³ for Process A; 99.47% and 0.4608 kW·h/Nm³ for Process B, respectively. It indicates the novel process can simultaneously achieve high purity and high H₂ recovery with low energy consumption.     

Safety analysis of leakage in a nuclear hydrogen production system

Due to its unique advantages, such as clean and pollution-free, hydrogen energy has gradually improved its energy transition position. Constructing nuclear hydrogen production systems is a necessary means to achieve large-scale hydrogen production, and the study of hydrogen leakage and diffusion behavior is critical to commercializing hydrogen production systems. In engineering practice, the distance between the hydrogen storage device and the nuclear power plant is an important indicator to measure the safety of nuclear hydrogen production. To study the influence of gas storage tank's own conditions and external environmental conditions on leakage diffusion, influencing factors such as wind speed, leakage direction, leakage diameter, leakage height, and leakage angle are discussed in the present study. By calculating severe working conditions combined with the above multiple factors, the longest distance of hydrogen diffusion is determined. Finally, peak overpressure impact generated by hydrogen explosion was evaluated, and the minimum separation distance required to avoid safety risks was predicted. The results demonstrate that when the wind direction is consistent with the leakage direction, and the leakage angle is 0°, the higher the wind speed, the larger the leakage diameter and the lower the leakage height, resulting in a longer diffusion distance. Under more extreme and severe working conditions, the diffusion distance of combustible hydrogen cloud can reach as far as 237 m. Once hydrogen diffusion explodes, the minimum separation distance required is about 338 m. This research provides an effective method for safety risk assessment of a nuclear hydrogen production system.     

Analysis of hazard area associated with hydrogen gas transmission pipelines

Hydrogen is considered to be the most important future energy carrier in many applications reducing significantly greenhouse gas emissions, but the safety issues associated with hydrogen applications need to be investigated and fully understood to be applicable as the carrier. Generally, the locations of hydrogen production and consumption are different. Hydrogen must be transported from the point of production to the point of use. Pipeline delivery is cheaper than all other methods for large quantities of hydrogen. The rupture of a hydrogen pipeline can lead to outcomes that can pose a significant threat to people and property in the immediate vicinity of the failure point. In this work, a simplified equation of hazard analysis is proposed for the pipeline transporting hydrogen, which relates the diameter, the operating pressure and the length of the pipeline to the size of the affected area in the event of a failure of the pipeline. The dominant hazards are thermal radiation from sustained fire and shock pressure from gas cloud explosion. For a transmission pipeline of hydrogen gas, the hazard area from the fire is slightly larger than by the other event. The hazard area is directly proportional to the operating pressure raised to the power one-half, and to the pipeline diameter. This simplified equation to estimate the hazard area will be a useful tool for safety management of hydrogen gas transmission pipelines.     

The effect of driving cycles and H2 production pathways on the lifecycle analysis of hydrogen fuel cell vehicle: A case study in South Korea

This study focuses on the simulation and analysis on the fuel economy of a hydrogen fuel cell vehicle, data collection and modeling to estimate greenhouse gas emission during its lifecycle. Since regenerative braking is a velocity related process, a car which is equipped with it can be significantly affected by the driving cycle. Therefore, the influence of five driving patterns on the fuel economy of a FCEV is investigated. Further prediction of life cycle emission is carried out by several hydrogen production pathways. The results indicate that the mileage of this FCEV for 1 complete charging can be extended by as much as 7% in fast shift driving mode with energy recovery of 30% during braking. The results also prove that hydrogen produced by natural gas in an on-site manner can reduce the lifecycle emission by more than 50%, comparing to that by Naphtha.     

锅炉脱盐水系统变频节能改造

在化工生产中,离心泵使用较为普遍,其出口压力往往要高于生产系统所需压力,常见做法是采用阀门降压,能耗较高.相比而言,变频调速能够降低离心泵出口压力过高问题,且能够节省阀门降压带来的能量损耗.针对兖矿国宏公司脱盐水系统,收集离心泵出口管道阀门前后压力数据,进行相关计算后得出节能效果.结合现场情况和运行经验,编制变频改造方案.改造完成后,再次收集相关数据,经过比较节能效果明显,达到预期目的.     

Effect of cascade storage system topology on the cooling energy consumption in fueling stations for hydrogen vehicles

One of the main obstacles of the diffusion of fuel cell electric vehicles (FCEV) is the refueling system. The new stations follow the refueling protocol from the Society of Automotive Engineers where the way to reach the target pressure is not explained. This work analyzes the thermodynamics of a hydrogen fueling station in order to study the effects of the cascade storage system topology on the energy consumption for the cooling facility. It is found that the energy consumption for cooling increases, expanding the total volume of the cascade storage system. Comparing the optimal and the worst volume configurations of the cascade storage tanks at different ambient temperatures, the energy saving is approximately 12% when the average ambient temperature is 20 °C and around 20% when the average ambient temperature is 30 °C. The energy consumption for cooling is significantly influenced by the topology of the cascade storage system and it is particularly relevant in the case of low daily-dispensed amount of hydrogen.     

High-pressure gaseous hydrogen permeation test method -property of polymeric materials for high-pressure hydrogen devices (1)-

Polymeric materials are widely used in hydrogen energy system such as FCEV and hydrogen refueling stations under high-pressure condition. The permeation property (coefficients of permeation, diffusion and solubility) of polymers under high-pressure hydrogen condition should be discussed as parameters to develop those devices. Also the property should be determined to understand influence of the compression by the pressure on polymer materials. A device which can measure gas permeation property of polymer materials accurately in equilibrium state under high-pressure environment is developed, and the reliability of the measurements is ensured. High-pressure hydrogen gas permeability characteristics up to 100 MPa are measured for high-density polyethylene. An advantage of the method is discussed comparing with the non-equilibrium state method, focusing on the hydrostatic pressure effect. Deterioration of hydrogen permeability is observed along with the decrease of diffusion coefficient, which is supposedly affected by hydrostatic compression effect with the increase of environment pressure.     

Geometric influence of perforated plate on premixed hydrogen-air flame propagation

Geometrical influence of the perforated plate on flame propagation in hydrogen-air mixtures with various equivalence ratios and initial pressures was experimentally investigated in a channel with the length of 1 m and the cross-section of 7 cm × 7 cm. The perforated plate has the same cross section and three thicknesses of 40 mm, 80 mm and 120 mm. High-speed schlieren photography was employed to capture the flame shape evolution and derive the flame tip velocity. High-speed piezoelectric pressure transducers were flush-mounted upstream and downstream of the perforated plate to measure the pressure transient. It was found that, with the perforated plate in the path of flame, flame undergoes either “go”, or “quench” propagation mode. The limit between these two was dependent on the geometrical size of the perforated plate and the initial conditions of mixtures. Both velocity and pressure were effectively attenuated with the increase in the perforated plate length. Moreover, for “go” propagation mode, the flame process through the perforated plate was characterized by three obvious stages: laminar flame stage, jet flame stage and turbulent flame stage. Whereas, only laminar flame stage was observed in the “quench” mode.     

Real-time optimization strategy by using sequence quadratic programming with multivariate nonlinear regression for a fuel cell electric vehicle

The energy management of a plug-in FCEV (Fuel Cell Electric Vehicle) strictly depends on the control of SOC (State of Charge) over a given trip distance. The SOC may be varied with the trip distance by updating an EF (Equivalent Factor), which is derived from ECMS (Equivalent Consumption Minimization Strategy). However, the EF is too complicated to estimate accurately in real-time with traditional method. A real-time optimization strategy by using SQP (Sequence Quadratic Programming) with MNLR (Multivariate Nonlinear Regression) is proposed for a plug-in FCEV. First, the real-time hydrogen consumption optimization problem for SOC trip distance adaptive is formulated by using ECMS. The EF is adjusted according to the trip distances and predefined SOC. Then, in order to improve the accuracy of EF, SQP method is utilized to optimize the fuel cell and battery efficiency. Thus, the MNLR is applied to construct the fuel cell and battery efficiency response surface models for real-time optimization application. Finally, numerical verification and hardware in loop experiments are conducted to validate the proposed strategy. The results indicate that the combination of SQP with MNLR made it possible to develop the proposed strategy capable of significantly improving the hydrogen economic performance of this FCEV.     

Neural network based optimization for cascade filling process of on-board hydrogen tank

Compressed hydrogen storage is widely used in hydrogen fuel cell vehicles (HFCVs). Cascade filling systems can provide different pressure levels associated with various source tanks allowing for a variable mass flow rate. To meet refueling performance objectives, safe and fast filling processes must be available to HFCVs. The main objective of this paper is to establish an optimization methodology to determine the initial thermodynamic conditions of the filling system that leads to the lowest final temperature of hydrogen in the on-board storage tank with minimal energy consumption. First, a zero-dimensional lumped parameter model is established. This simplified model, implemented in Matlab/Simulink, is then used to simulate the flow of hydrogen from cascade pressure tanks to an on-board hydrogen storage tank. A neural network is then trained with model calculation results and experimental data for multi-objective optimization. It is found to have good prediction, allowing the determination of optimal filling parameters. The study shows that a cascade filling system can well refuel the on-board storage tank with constant average pressure ramp rate (APRR). Furthermore, a strong pre-cooling system can effectively lower the final temperature at a cost of larger energy consumption. By using the proposed neural network, for charging times less than 183s, the optimization procedure predicts that the inlet temperature is 259.99–266.58 K, which can effectively reduce energy consumption by about 2.5%.