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.     

Optimization of the overall energy consumption in cascade fueling stations for hydrogen vehicles

Hydrogen fueling stations are emerging around and in larger cities in Europe and United States together with a number of hydrogen vehicles. The most stations comply with the refueling protocol made by society of automotive engineers and they use a cascade fueling system on-site for filling the vehicles. The cascade system at the station has to be refueled as the tank sizes are limited by the high pressures. The process of filling a vehicle and afterward bringing the tanks in refueling station back to same pressures, are called a complete refueling cycle. This study analyzes power consumption of refueling stations as a function of number of tanks, volume of the tanks and the pressure in the tanks. This is done for a complete refueling cycle. It is found that the energy consumption decreases with the number of tanks approaching an exponential function. The compressor accounts for app. 50% of the energy consumption. Going from one tank to three tanks gives an energy saving of app. 30%. Adding more than four tanks the energy saving per extra added tank is less than 4%. The optimal numbers of tanks in the cascade system are three or four.     

Dynamic simulation for optimal hydrogen refueling method to Fuel Cell Vehicle tanks

A dynamic simulation approach to investigate an optimal hydrogen refueling method is proposed. The proposed approach simulates a transient temperature, pressure and mass flow rate of hydrogen flowing inside filling equipment in an actual station during the refueling process to an Fuel Cell Vehicle (FCV) tank. The simulation model is the same as in an actual hydrogen refueling station (HRS), and consists of a Break-Away, a hose, a nozzle, pipes and an FCV tank. Therefore, we can set actual configurations and thermal properties to the simulation model, and then simulate the temperature, pressure and mass flow rate of hydrogen passing through each position based on the supply conditions (temperature and pressure) at the Break-Away. In this study, the simulated temperature, pressure and mass flow rate are compared with the corresponding experimental data. Therefore, we show that the dynamic simulation approach can accurately obtain those values at each position during the refueling process and is an effective step in proposing the optimal refueling method.     

Impact of hydrogen refueling configurations and market parameters on the refueling cost of hydrogen

The cost of hydrogen in early fuel cell electric vehicle (FCEV) markets is dominated by the cost of refueling stations, mainly due to the high cost of refueling equipment, small station capacities, lack of economies of scale, and low utilization of the installed refueling capacity. Using the hydrogen delivery scenario analysis model (HDSAM), this study estimates the impacts of these factors on the refueling cost for different refueling technologies and configurations, and quantifies the potential reduction in future hydrogen refueling cost compared to today's cost in the United States. The current hydrogen refueling station levelized cost, for a 200 kg/day dispensing capacity, is in the range of $6–$8/kg H₂ when supplied with gaseous hydrogen, and $8–$9/kg H₂ for stations supplied with liquid hydrogen. After adding the cost of hydrogen production, packaging, and transportation to the station's levelized cost, the current cost of hydrogen at dispensers for FCEVs in California is in the range of $13–$15/kg H₂. The refueling station capacity utilization strongly influences the hydrogen refueling cost. The underutilization of station capacity in early FCEV markets, such as in California, results in a levelized station cost that is approximately 40% higher than it would be in a scenario where the station had been fully utilized since it began operating. In future mature hydrogen FCEV markets, with a large demand for hydrogen, the refueling station's levelized cost can be reduced to $2/kg H₂ as a result of improved capacity utilization and reduced equipment cost via learning and economies of scale.     

Queuing-based approach for optimal dispenser allocation to hydrogen refueling stations

Dispenser allocation to hydrogen refueling stations aims at minimizing the number of dispensers while ensuring satisfactory performance of vehicle queues during the peak hour of a peak day. A queuing model is developed in this study to evaluate the queuing performance at such stations by incorporating the statistical and thermodynamic characteristics of refueling. An optimization framework is proposed to determine the minimal number of dispensers required to meet the upper limits imposed on two important performance measures: mean waiting time and mean queue length. Reasonable upper limits are provided for 70 MPa stations according to the effects of dispenser allocation and station capacity on queuing performance. Server (dispenser nozzle) utilization under the optimal dispenser allocation generally increases with an increase in station size and tends to exceed 50% for large stations. The proposed approach can offer significant performance improvements for small stations and considerable savings in the number of dispensers for large ones.     

Numerical simulation of temperature rise within hydrogen vehicle cylinder during refueling

Basing on the Spallart-Allmaras turbulence model and the real gas equation of state, a numerical model is proposed in this paper to study the mechanism of temperature rise within hydrogen vehicle cylinder during refueling. The model is validated by comparing calculated results with experimental data. With the validated model, the effect of mass filling rate, initial pressure within cylinder and ambient temperature on the maximum temperature rise during refueling are investigated. The study shows that the maximum temperature rise increases with the growth in mass filling rate and ambient temperature, while it descends as the initial pressure increases. Finally, an empirical formula is obtained by fitting numerical results and effective methods for temperature control is given.     

The impact of hydrogen refueling station subsidy strategy on China's hydrogen fuel cell vehicle market diffusion

Lack of hydrogen refueling stations (HRSs) has hindered the diffusion of hydrogen fuel cell vehicles (HFCVs) in the Chinese transport market. By combining the agent-based model (ABM) and the experience weighted attraction (EWA) learning algorithm, this paper explores the impact of government subsidy strategy for HRSs on the market diffusion of HFCVs. The actions of the parties (government, HRS planning department and consumers) and their interactions are taken into account. The new model suggests dynamic subsidy mode based on EWA algorithm yields better results than static subsidy mode: HFCV purchases, HRS construction effort, total number of HRSs and expected HRS planning department profits all outperform static data by around 27%. In addition, choosing an appropriate initial subsidy strategy can increase the sales of HFCVs by nearly 40%. Early investment from government to establish initial HRSs can also increase market diffusion efficiency by more than 76.7%.     

Vehicle refueling with liquid hydrogen thermal compression

We have modeled an approach for dispensing pressurized hydrogen to 350 and/or 700 bar vehicle vessels. Instead of relying on compressors, this concept stores liquid hydrogen in cryogenic pressure vessels where pressurization occurs through heat transfer, reducing the station energy footprint from 12 kW h/kgH₂ of energy from the US grid mix to 1.5–2 kW h/kgH₂ of heating. This thermal compression station presents capital cost and reliability advantages by avoiding the expense and maintenance of high-pressure hydrogen compressors, at the detriment of some evaporative losses. The total installed capital cost for a 475 kg/day thermal compression hydrogen refueling station is estimated at about $611,500, an almost 60% cost reduction over today's refueling station cost. The cost for 700 bar dispensing is $5.23/kg H₂ for a conventional station vs. $5.45/kg H₂ for a thermal compression station. If there is a demand for 350 bar H₂ in addition to 700 bar dispensing, the cost of dispensing from a thermal compression station drops to $4.81/kg H₂, which is similar to the cost of a conventional station that dispenses 350 bar H₂ only. Thermal compression also offers capacity flexibility (wide range of pressure, temperature, and station demand) that makes it appealing for early market applications.     

Thermodynamic modeling of hydrogen refueling for heavy-duty fuel cell buses and comparison with aggregated real data

The foreseen uptake of hydrogen mobility is a fundamental step towards the decarbonization of the transport sector. Under such premises, both refueling infrastructure and vehicles should be deployed together with improved refueling protocols. Several studies focus on refueling the light-duty vehicles with 10 kg_H2 up to 700 bar, however less known effort is reported for refueling heavy-duty vehicles with 30–40 kg_H2 at 350 bar. The present study illustrates the application of a lumped model to a fuel cell bus tank-to-tank refueling event, tailored upon the real data acquired in the 3Emotion Project. The evolution of the main refueling quantities, such as pressure, temperature, and mass flow, are predicted dynamically throughout the refueling process, as a function of the operating parameters, within the safety limits imposed by SAE J2601/2 technical standard. The results show to refuel the vehicle tank from half to full capacity with an Average Pressure Ramp Rate (APRR) equal to 0.03 MPa/s are needed about 10 min. Furthermore, it is found that the effect of varying the initial vehicle tank pressure is more significant than changing the ambient temperature on the refueling performances. In conclusion, the analysis of the effect of different APRR, from 0.03 to 0.1 MPa/s, indicate that is possible to safely reduce the duration of half-to-full refueling by 62% increasing the APRR value from 0.03 to 0.08 MPa/s.     

Research on sealing performance and self-acting valve reliability in high-pressure oil-free hydrogen compressors for hydrogen refueling stations

Piston ring sealing and valve design play an important role in high-pressure oil-free reciprocating compressors for hydrogen refueling stations. The severe non-uniformity of the pressure distribution was suggested to be the root cause of the premature failure of the sealing rings, and therefore a mathematical model was established to simulate the unsteady flow within the gaps of piston rings, based on which the pressure distribution was obtained and the mechanism of the non-uniform abrasion of the rings was disclosed. The method to equalize the pressure difference through each ring was proposed by re-distributing the cut size of each ring, and it was validated experimentally. Aiming at the problem that the self-acting valves in hydrogen compressors could be easily destroyed by severe impact, this paper investigated the motion and impact of valves theoretically and experimentally, based on which the methodology was explored to design the parameters of valves for hydrogen compressors.     

Design proposal for hydrogen refueling infrastructure deployment in the Northeastern United States

Fuel cell vehicles (FCVs) are expected to be commercially available on the world market in 2015, therefore, introducing hydrogen-refueling stations is an urgent issue to be addressed. This paper proposes deployment plan of hydrogen infrastructure for the success of their market penetration in the Northeastern United States. The plan consists of three-timeline stages from 2013 to 2025 and divides the designated region into urban area, suburban area and area adjacent to expressway, so that easy to access to hydrogen stations can be realized. Station is chosen from four types of stations: off-site station, urban-type on-site station, suburban-type on-site station and portable station, associated with growing demand. In addition, on-site station is used as hydrogen production factory for off-site station to save total investment. This deployment plan shows that 83% of urban residents can reach station within 10 min in 2025, and that more than 90% people especially in four major cities: Boston, New York City, Philadelphia, and Washington, D.C. can get to station within 10 min by Geographic Information System (GIS) calculation.     

Effect of wind condition on unintended hydrogen release in a hydrogen refueling station

Ambient condition, especially the wind condition, is an important factor to determine the behavior of hydrogen diffusion during hydrogen release. However, only few studies aim at the quantitative study of the hydrogen diffusion in a wind-exist condition. And very little researches aiming at the variable wind condition have been done. In this paper, the hydrogen diffusion in different wind condition which including the constant wind velocity and the variable wind velocity is investigated numerically. When considering the variable wind velocity, the UDF (user defined function) is compiled. Characteristics of the FGC (flammable gas cloud) and the HMF (hydrogen mass fraction) are analyzed in different wind condition and comparisons are made with the no-wind condition. Results indicate that the constant wind velocity and the variable wind velocity have totally different effect for the determination of hydrogen diffusion. Comparisons between the constant wind velocity and the variable wind velocity indicate that the variable wind velocity may cause a more dangerous situation since there has a larger FGC volume. More importantly, the wind condition has a non-negligible effect when considering the HMF along the radial direction. As the wind velocity increases, the distribution of the HMF along the radial direction is not Gaussian anymore when the distance between the release hole and the observation line exceeds to a critical value. This work can be a supplement of the research on the hydrogen release and diffusion and a valuable reference for the researchers.     

The cavity profile of a diaphragm compressor for a hydrogen refueling station

A low flow rate and short diaphragm life are the two disadvantages of diaphragm compressors when applied in hydrogen refueling stations. A new generatrix of the cavity profile of a diaphragm compressor was developed in this study to increase the cavity volume and decrease the diaphragm radial stress. A reduction in the diaphragm radial stress that resulted from the new design was validated by experiment and numerical simulation. The volumes of the cavities with different generatrices and the radial stress distribution of the diaphragm were investigated under various design conditions. The results indicated that the volume of the cavity with the new generatrix was approximately 10% larger than that with a traditional generatrix at the same allowable stress and cavity radius. At a similar cavity volume and radius, the radial stress values of the diaphragm in the cavity with the new generatrix were low. The decrease rate of the maximal radial stress of the diaphragm in the cavity with the new generatrix reached 13.8%. In the diaphragm centric region, where additional stress was induced by discharge holes, the maximal radial stress decrease rate reached 19.6%.     

Two-tier pressure consolidation operation method for hydrogen refueling station cost reduction

An operation strategy known as two-tier “pressure consolidation” of delivered tube-trailers (or equivalent supply storage) has been developed to maximize the throughput at gaseous hydrogen refueling stations (HRSs) for fuel cell electric vehicles (FCEVs). The high capital costs of HRSs and the consequent high investment risk are deterring growth of the infrastructure needed to promote the deployment of FCEVs. Stations supplied by gaseous hydrogen will be necessary for FCEV deployment in both the near and long term. The two-tier pressure consolidation method enhances gaseous HRSs in the following ways: (1) reduces the capital cost compared with conventional stations, as well as those operating according to the original pressure consolidation approach described by Elgowainy et al. (2014) [1], (2) minimizes pressure cycling of HRS supply storage relative to the original pressure consolidation approach; and (3) increases use of the station's supply storage (or delivered tube-trailers) while maintaining higher state-of-charge vehicle fills.     

Quantitative risk assessment using a Japanese hydrogen refueling station model

Although hydrogen refueling stations (HRSs) are becoming widespread across Japan and are essential for the operation of fuel cell vehicles, they present potential hazards. A large number of accidents such as explosions or fires have been reported, rendering it necessary to conduct a number of qualitative and quantitative risk assessments for HRSs. Current safety codes and technical standards related to Japanese HRSs have been established based on the results of a qualitative risk assessment and quantitative effectiveness validation of safety measures over ten years ago. In the last decade, there has been much development in the technologies of the components or facilities used in domestic HRSs and much operational experience as well as knowledge to use hydrogen in HRSs safely have been gained through years of commercial operation. The purpose of the present study is to conduct a quantitative risk assessment (QRA) of the latest HRS model representing Japanese HRSs with the most current information and to identify the most significant scenarios that pose the greatest risks to the physical surroundings in the HRS model. The results of the QRA show that the risk contours of 10^?3 and 10^?4 per year were confined within the HRS boundaries, whereas the risk contours of 10^?5 and 10^?6 per year are still present outside the HRS. Comparing the breakdown of the individual risks (IRs) at the risk ranking points, we conclude that the risk of jet fire demonstrates the highest contribution to the risks at all of the risk ranking points and outside the station. To reduce these risks and confine the risk contour of 10^?6 per year within the HRS boundaries, it is necessary to consider risk mitigation measures for jet fires.     

Impact of hydrogen SAE J2601 fueling methods on fueling time of light-duty fuel cell electric vehicles

Hydrogen fuel cell electric vehicles (HFCEVs) are zero-emission vehicles (ZEVs) that can provide drivers a similar experience to conventional internal combustion engine vehicles (ICEVs), in terms of fueling time and performance (i.e. power and driving range). The Society of Automotive Engineers (SAE) developed fueling protocol J2601 for light-duty HFCEVs to ensure safe vehicle fills while maximizing fueling performance. This study employs a physical model that simulates and compares the fueling performance of two fueling methods, known as the “lookup table” method and the “MC formula” method, within the SAE J2601 protocol. Both the fueling methods provide fast fueling of HFCEVs within minutes, but the MC formula method takes advantage of active measurement of precooling temperature to dynamically control the fueling process, and thereby provides faster vehicle fills. The MC formula method greatly reduces fueling time compared to the lookup table method at higher ambient temperatures, as well as when the precooling temperature falls on the colder side of the expected temperature window for all station types. Although the SAE J2601 lookup table method is the currently implemented standard for refueling hydrogen fuel cell vehicles, the MC formula method provides significant fueling time advantages in certain conditions; these warrant its implementation in future hydrogen refueling stations for better customer satisfaction with fueling experience of HFCEVs.     

Optimal operation of a photovoltaic generation-powered hydrogen production system at a hydrogen refueling station

As the popularity of fuel cell vehicles continues to rise in the global market, production and supply of low-carbon hydrogen are important to mitigate CO₂ emissions. We propose a design for a hydrogen refueling station with a proton exchange membrane electrolyzer (PEM-EL)-based electrolysis system (EL-System) and photovoltaic generation (PV) to supply low-carbon hydrogen. Hydrogen is produced by the EL-System using electricity from PV and the power grid. The system was formulated as a mixed integer linear programming (MILP) model to allow analysis of optimal operational strategies. Case studies with different objective functions, CO₂ emission targets, and capacity utilization of the EL-System were evaluated. Efficiency characteristics of the EL-System were obtained through measurements. The optimized operational strategies were evaluated with reference to three evaluation indices: CO₂ emissions, capacity utilization, and operational cost of the system. The results were as follows: 1) Regardless of the objective function, the EL-System generally operated in highest efficiency state, and optimal operation depended on the efficiency characteristics of the EL-System; 2) mitigation of CO₂ emissions and increase in capacity utilization of the EL-System required trade-offs; and 3) increased capacity utilization of the EL-System showed two opposing effects on hydrogen retail price.     

On optimal investment strategies for a hydrogen refueling station

The uncertainty and cost of changing from a fossil-fuel-based society to a hydrogen-based society are considered to be extensive obstacles to the introduction of fuel cell vehicles (FCVs). The absence of existing profitable refueling stations has been shown to be one of the major barriers. This paper investigates methods for calculating an optimal transition from a gasoline refueling station to future methane and hydrogen combined use with an on site small-scale reformer for methane. In particular, we look into the problem of matching the hydrogen capacity of a single refueling station to an increasing demand. Based on an assumed future development scenario, optimal investment strategies are calculated. First, a constant utilization of the hydrogen reformer is assumed in order to find the minimum hydrogen production cost. Second, when considerations such as periodic maintenance are taken into account, optimal control is used to concurrently find both a short term equipment variable utilization for one week and a long term strategy. The result is a minimum hydrogen production cost of $4–6/kg, depending on the number of reinvestments during a 20 year period. The solution is shown to yield minimum hydrogen production cost for the individual refueling station, but the solution is sensitive to variations in the scenario parameters.     

Evaluating uncertainty in accident rate estimation at hydrogen refueling station using time correlation model

Hydrogen, as a future energy carrier, is receiving a significant amount of attention in Japan. From the viewpoint of safety, risk evaluation is required in order to increase the number of hydrogen refueling stations (HRSs) implemented in Japan. Collecting data about accidents in the past will provide a hint to understand the trend in the possibility of accidents occurrence by identifying its operation time However, in new technology; accident rate estimation can have a high degree of uncertainty due to absence of major accident direct data in the late operational period. The uncertainty in the estimation is proportional to the data unavailability, which increases over long operation period due to decrease in number of stations. In this paper, a suitable time correlation model is adopted in the estimation to reflect lack (due to the limited operation period of HRS) or abundance of accident data, which is not well supported by conventional approaches. The model adopted in this paper shows that the uncertainty in the estimation increases when the operation time is long owing to the decreasing data.