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%.     

Thermodynamic analysis of hydrogen tank filling. Effects of heat losses and filling rate optimization

A thermodynamic analysis of the refueling of a gaseous fuel tank and a thermal analysis of heat losses through tank walls is presented. The objective of the thermodynamic analysis is to compare the temperature and pressure evolutions coming from different equations of state and from thermodynamic tables. This comparison is performed with nitrogen and hydrogen and the compression is assumed adiabatic. It is shown that the ideal-gas assumption results in under-prediction of the tank temperature and pressure for hydrogen but in over-prediction for nitrogen. An approximate analytical expression of the Redlich–Kwong equation of state is given which is in very good agreement with thermodynamic tables. To handle heat losses, different approaches are used and compared. First, a global thermal conductance is introduced which allows deriving analytical expressions. Then, a thermal nodal modeling of tank walls is proposed to take into account thermal capacity effects. Finally a 1D semi-infinite modeling of the tank walls is presented. Finally, this model is used to optimize mass flow rate in order to limit the temperature rise during the filling process.     

CFD model performance benchmark of fast filling simulations of hydrogen tanks with pre-cooling

High gas temperatures can be reached inside a hydrogen tank during the filling process because of the large pressure increase (up to 70–80 MPa) and because of the short time (∼3 min) of the process. High temperatures can potentially jeopardize the structural integrity of the storage system and one of the strategies to reduce the temperature increase is to pre-cool the hydrogen before injecting it into the tank. Computational Fluid Dynamics (CFD) tools have the capabilities of capturing the flow field and the temperature rise in the tank. The results of CFD simulations of fast filling with pre-cooling are shown and compared with experimental data to assess the accuracy of the CFD model.     

Fast filling strategy of type III on-board hydrogen tank based on time-delayed method

In order to study the fast filling problem of the type III on-board hydrogen tank, a 3D computational fluid dynamics (CFD) simulation model is proposed. Several simulation calculations are completed to simulate the fast filling process under different initial conditions. In order to control the temperature rise during the fast filling process, the effects of different mass flow rates are studied. Based on the control of mass flow rate, various time-delayed filling strategies for different conditions are proposed to meet the requirement of shortening the filling time as much as possible without exceeding the maximum temperature limit. It is found that if the delay duration is determined, how the filling time is allocated has little effect on the final temperature rise. The proposed strategy can complete the filling within 155s in a general environment, which saves 62% of the time compared with the filling with constant mass flow rate. This research provides the theoretical basis and technical support for mass flow control strategies of fast filling in the hydrogen refueling stations and has guiding significance for the actual filling process of large-capacity hydrogen tanks.     

Numerical study on fast filling of 70 MPa type III cylinder for hydrogen vehicle

There will be significant temperature rise within hydrogen vehicle cylinder during the fast filling process. The temperature rise should be controlled under the temperature limit (85 °C) of the structure material (set by ISO/TS 15869), because it may lead to the failure of the structure. In this paper, a 2-dimensional axisymmetric computational fluid dynamics (CFD) model for fast filling of 70 MPa hydrogen vehicle cylinder is presented. The numerical simulations are based on the modified standard k − ? turbulence model. In addition, both the equation of state for hydrogen gas and the thermodynamic properties are calculated by National Institute of Standards and Technology (NIST) database: REFPROP 7.0. The thermodynamic responses of fast filling with different pressure-rise patterns and filling times within type III cylinder have been analyzed in detail.     

CFD analysis of fast filling scenarios for 70 MPa hydrogen type IV tanks

High injection pressure is combined with high refueling rate for vehicles storing pressurized gaseous hydrogen onboard. As a drawback, high temperatures are developed inside the tank, which can jeopardize the structural integrity of the storage system. Computational Fluid Dynamics (CFD) codes already proved to be a valuable tool for predicting the temperature distribution within the tank during fast refueling. Results of hydrogen fast filling CFD simulations for a type IV tank, filled to 70 MPa at different working conditions are presented as follow up of the CFD model validation performed against experimental data. Alternative rates of pressure rise, adiabatic and cold filling are investigated to evaluate the effect on maximum hydrogen temperatures inside the tank. Results confirmed that the developed CFD model could be a suitable tool for investigating fast filling scenarios when experimental data are not yet available or of difficult realization.     

Conditioning of hydrogen storage by continuous solar adsorption in activated carbon AX-21 with simultaneous production

The capacity of hydrogen storage by solar adsorption in activated carbon AX-21 and filling rate with simultaneous production have been conditioned under a minimum pressure, to nullify the cost of energy supplied to compressor. A gas accumulator tank connected to electrolyzer and continuous adsorption beds have been proposed in the process scheme. Minimum pressure required for the tank at an ambient filling temperature fixed to 25 °C is only 2 bar. While at atmospheric filling pressure the corresponding value of filling temperature is found to be 5 °C. However, a cooling fluid at low temperature for adsorbent bed during the adsorption process will be an efficient way for increasing the stored amount of hydrogen. Almost 4.5 kg of hydrogen can be stored in an adsorbent mass of 200 kg. The adsorption flow rate has been also modelled to be controlled for being adapted to production rate.     

Thermodynamic analysis of filling compressed gaseous hydrogen storage tanks

This paper reports a thermodynamic analysis of filling a fuel tank with compressed gaseous hydrogen. The analysis is based on energy and exergy methods. A parametric study is performed to investigate the effect of initial conditions on the exergy destruction and exergy efficiency of filling processes. The transient filling process is studied to determine the temperature and pressure changes inside the storage tank during filling.     

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.     

Assessment of CFD models for hydrogen fast filling simulations

High injection pressures are used during the re-fueling process of vehicle tanks with compressed hydrogen, and consequently high temperatures are generated in the tank, potentially jeopardizing the system safety. Computational Fluid Dynamics (CFD) tools can help in predicting the temperature rise within vehicle tanks, providing complete and detailed 3D information on flow features and temperature distribution. In this framework, CFD simulations of hydrogen fast filling at different working conditions are performed and the accuracy of the numerical models is assessed against experimental data for a type 4 tank up to 70 MPa.     

Estimation of final hydrogen temperature from refueling parameters

Compressed hydrogen storage is currently widely used in fuel cell vehicles due to its simplicity in tank structure and refueling process. For safety reason, the final gas temperature in the hydrogen tank during vehicle refueling must be maintained under a certain limit, e.g., 85 °C. Many experiments have been performed to find the relations between the final gas temperature in the hydrogen tank and refueling conditions. The analytical solution of the hydrogen temperature in the tank can be obtained from the simplified thermodynamic model of a compressed hydrogen storage tank, and it serves as function formula to fit experimental temperatures. From the analytical solution, the final hydrogen temperature can be expressed as a weighted average form of initial temperature, inflow temperature and ambient temperature inspired by the rule of mixtures. The weighted factors are related to other refueling parameters, such as initial mass, initial pressure, refueling time, refueling mass rate, average pressure ramp rate (APRR), final mass, final pressure, etc. The function formula coming from the analytical solution of the thermodynamic model is more meaningful physically and more efficient mathematically in fitting experimental temperatures. The simple uniform formula, inspired by the concept of the rule of mixture and its weighted factors obtained from the analytical solution of lumped parameter thermodynamics model, is representatively used to fit the experimental and simulated results in publication. Estimation of final hydrogen temperature from refueling parameters based on the rule of mixtures is simple and practical for controlling the maximum temperature and for ensuring hydrogen safety during fast filling process.     

Experimental studies on temperature rise within a hydrogen cylinder during refueling

In this research, experiments were performed to investigate the thermal behaviors such as temperature rise and distributions inside 35 MPa, 150 L hydrogen storage cylinders during its refueling. The main factors affecting the temperature rise in the fast fill process such as the mass filling rate and initial pressure in the cylinder were considered. The experimental results show that the mass filling rate is a constant when the ratio of the pressure in the tank to the cylinder is higher than 1.7, and the mass filling rate decreases when the ratio is lower than 1.7; the temperature inside the cylinder increases nonlinearly in the filling process and the maximum value of temperature rise at the interface of the cylinder exists in the caudal region; the temperature rise reaches a larger value with a lower initial pressure in the cylinder or a higher mass filling rate. Furthermore, the limit of mass filling rate in the case of different ambient temperature was obtained.     

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.     

Investigation on no-vent filling process of liquid hydrogen tank under microgravity condition

In order to investigate the no-vent filling performance under microgravity, the computational fluid dynamic (CFD) method is introduced to the study, where a model aiming at filling a liquid hydrogen (LH₂) receiver tank is especially established. In this model, the solid and fluid regions are considered together to predict the coupled heat transfer process. The phase change effect during the filling process is also taken into account by embedding a pair of mass and heat transfer models into the CFD software FLUENT, one of which involves liquid flash driven by pressure difference between the fluid saturated pressure and the tank pressure, and the other one indicates and calculates the evaporation–condensation process driven by temperature difference between fluid and its saturated state. This CFD model, verified by experimental data, could accurately simulate the no-vent filling process with good flexibility. Moreover, no-vent filling processes under different gravities are comparatively analyzed and the effects of four factors including inlet configuration, inlet liquid temperature, initial wall temperature and inlet flow rate, are discussed, respectively. Main conclusions could be made as follows: 1) Compared to the situations in normal gravity, the no-vent filling in microgravity experiences a more adequate liquid–vapor mix, which results in a more steady pressure response and better filling performance. 2) Inlet configuration seems to have negligible effect on the no-vent filling performance under microgravity since liquid could easily reach the tank wall and then cause a sufficient fluid-wall contact under any inlet condition. 3) Higher initial tank wall temperature may directly cause a higher pressure rise in the beginning, while this effect on the final pressure is not significant. Sufficient precooling and reasonable inlet liquid subcooled degree are suggested to guarantee the reliability and efficiency of the no-vent fill under microgravity.     

Advanced turbulence modeling improves thermal gradient prediction during compressed hydrogen tank filling

In order to use gaseous hydrogen for mobility of light and heavy duty vehicles, the standard J2601 from the Society of Automotive Engineers (SAE) recommends that the temperature in the tank must not exceed 85 °C for safety reasons. Prior experiments reported that a vertical thermal stratification can occur during the filling of horizontal tanks under specific conditions. Thermodynamic modeling of hydrogen tank filling can predict the average gas temperature but not the onset of stratification. In a previous study, the computational fluid dynamics (CFD) software OpenFOAM was used to carry out simulations of hydrogen filling for a type IV 37 L tank. The CFD results, by comparison with experimental results, were capable to predict the rise of the thermal stratification with however an underestimation of thermal gradient magnitudes. The maximal temperature predicted at the end of the filling was 15.05 °C bellow the experimental measurements. In this work, the k − ω SST turbulence model is replaced by the k − ω SST SAS turbulence model to limit the prediction of high levels of eddy-viscosity in stagnation areas which over-diffuses the temperature. By using the same mesh as in the above mentioned study, (651 482 cells in the fluid region and 449 126 cells in solid regions), the k − ω SST SAS turbulence model is found to be more appropriate for CFD simulation of tank filling as it predicts a thermal gradient magnitude in the gas in better agreement with experimental measurements than the k − ω SST turbulence model for a similar time of simulation. The maximal temperature predicted at the end of the filling is 2.17 °C bellow the experimental measurements.     

Three dimensional numerical computations on the fast filling of a hydrogen tank under different conditions

Hydrogen-fueled vehicles offer a clean and efficient alternative for transportation. Compressed gas in high pressure tanks is a popular storage mode for hydrogen fuel. Time required for filling a hydrogen tank for vehicular applications should be short. But quick filling of hydrogen tanks at high pressures can result in high gas temperatures which can damage the tank and lead to its rupture. Hence the real time monitoring of gas temperature is essential during filling. This paper reports the findings of numerical simulation of filling process of hydrogen tanks. Real gas effects are considered. Local temperature distribution in the tank is obtained at different durations of the fill. Effect of changes in ambient temperature and initial and inlet gas temperatures is studied. Results of the study can aid in optimizing the filling time and in identifying the most suitable locations for the feedback devices within on-board hydrogen tanks.     

Final hydrogen temperature and mass estimated from refueling parameters

The final temperature and mass of compressed hydrogen in a tank after a refueling process can be estimated using the analytical solutions of a lumped parameter thermodynamic model of high pressure compressed hydrogen storage system. The effects of three single refueling parameters (ambient temperature, initial pressure and mass flow rate) and three pairs of the refueling parameters on the final hydrogen temperature are studied, for both 35 MPa and 70 MPa tanks. Overall expressions for the final hydrogen temperature, expressed as a function of the three factors, are obtained. The formulae for the final hydrogen temperature provide an excellent representation of the reference data. The effects of the refueling parameters (mass flow rate, initial pressure and inflow temperature) on the final hydrogen mass are determined from the physical model. An overall expression of the final hydrogen mass is also obtained. The final hydrogen temperature can be controlled by reducing the ambient temperature or the mass flow rate, or increasing the initial pressure. The final hydrogen mass can be maximized by reducing the mass flow rate or the inflow temperature, or increasing the initial pressure. This study provides simple engineering formulae to assist in establishing refueling protocols for gaseous hydrogen vehicles.     

Numerical simulation of hydrogen filling process in novel high-pressure microtube storage device

Novel high-pressure microtube hydrogen storage device has higher hydrogen storage density and safety than conventional hydrogen tanks. A one-dimensional numerical model for hydrogen filling process in microtubes is established, with reasonable calculation methods and accurate physical properties adopted. Based on the analysis of flow parameters variations, three stages of the filling process are summarized. At the beginning of the filling process, the maximum temperature appears at the inlet, but the average temperature does not rise significantly during the whole process. The effects of microtube length, filling pressure and environmental temperature are investigated and discussed. The results show that excessively long microtubes greatly increase the filling time and higher filling pressure reduces the filling time and improves the filling efficiency. The microtube hydrogen storage device achieves higher hydrogen storage density and filling efficiency in lower temperature mediums. It reveals that high filling pressure, low temperature encapsulation and reasonable microtube size design are the future development directions of microtube hydrogen storage for better application.     

Characteristics of heat transfer and temperature rise of hydrogen during rapid hydrogen filling at high pressure

An experiment has been done to measure the rise in temperature of a gas during filling a tank at high pressure. The experimental condition is that filling gases are nitrogen and hydrogen at a pressure of 5 to 35 MPa and at a filling mass of G=45 to 324 g/min for hydrogen. The temperatures are measured either horizontally or vertically at five positions in the tank. It is found that heat loss transferred from compressed gas to the tank wall has a significant effect on the rise in the filled gas temperature. The heat transfer coefficient is estimated after the end of filling and is about α_h=270 W/(m²K) for the hydrogen at 35 MPa. A theoretical procedure is proposed to calculate the temperature increase of the gas on a basis of assumption that the gas temperature in the tank is uniform at any time, and the heat transfer coefficient is given. The calculation shows that the temperature is in reasonable agreement with the measured temperatures by assuming α_h=500 W/(m²K) during the filling of hydrogen at 35 MPa, although the estimated heat loss after the end of filling becomes larger than the actual one. © 2006 Wiley Periodicals, Inc. Heat Trans Asian Res, 36(1): 13–27, 2007; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20140     

Review on the research of hydrogen storage system fast refueling in fuel cell vehicle

A comprehensive review of the hydrogen storage systems and investigations performed in search for development of fast refueling technology for fuel cell vehicles are presented. Nowadays, hydrogen is considered as a good and promising energy carrier and can be stored in gaseous, liquid or solid state. Among the three ways, high pressure (such as 35 MPa or 70 MPa) appears to be the most suitable method for transportation due to its technical simplicity, high reliability, high energy efficiency and affordability. However, the refueling of high pressure hydrogen can cause a rapid increase of inner temperature of the storage cylinder, which may result not only in a decrease of the state of charge (SOC) but also in damages to the tank walls and finally to safety problems. In this paper, the theoretical analysis, experiments and simulations on the factors related to the fast refueling, such as initial pressure, initial temperature, filling rate and ambient temperature, are reviewed and analyzed. Understanding the potential relationships between these parameters and the temperature rise may shed a light in developing novel controlling strategies and innovative routes for hydrogen tank fast filling.