Investigation of precooling unit design options in hydrogen refueling station for heavy-duty fuel-cell electric vehicles

Poudel, Sajag; Tun, Hla; Reddi, Krishna; Elgowainy, Amgad

doi:10.1016/j.ijhydene.2024.02.197

Investigation of precooling unit design options in hydrogen refueling station for heavy-duty fuel-cell electric vehicles

Journal Article · Sat Mar 02 00:00:00 EST 2024 · International Journal of Hydrogen Energy

DOI:https://doi.org/10.1016/j.ijhydene.2024.02.197· OSTI ID:2475289

^[1]; Tun, Hla ^[1]; Reddi, Krishna ^[1]; ^[1]

Argonne National Laboratory (ANL), Argonne, IL (United States)

Precooling gaseous hydrogen fuel to a cold temperature before refueling a heavy-duty (HD) hydrogen fuel cell electric vehicle (HFCEV) is essential to avoid overheating the vehicle tank, as well as achieving a high state of charge (SOC). Because a large volume of hydrogen is dispensed during each fill, the need for a shorter fill time amplifies the need to precool each load for refueling a HFCEV. Thus, the design and operation of a precooling unit (PCU), as well as the associated capital and operating costs, plays a pivotal role in any plans for heavy-duty hydrogen refueling stations. Here, in this paper, we present a thermodynamic and technoeconomic analysis of a PCU in a gaseous hydrogen refueling station (HRS) for HD HFCEVs. By employing Argonne National Laboratory's hydrogen station cost optimization and performance evaluation (H2SCOPE) model, the refueling of 50 kg of hydrogen on-board type IV tank at ambient temperatures of 15–45 °C and varying fill rates is simulated. The required degree of precooling temperature to obtain either 100% or the maximum possible SOC is obtained from the simulation. Additionally, the simulation results demonstrate that the average flow rate of hydrogen is approximately 40% lower than the maximum flow rate during a typical fill; which motivates further evaluation of the instantaneous hydrogen mass flow rate profile and suggests the scope of improving precooling unit design. Accordingly, a hybrid strategy of precooling hydrogen has been proposed to address the cooling load by sizing the refrigeration unit for the average flow rate of hydrogen, while supplementing the above average peak hydrogen flow cooling load through thermal buffering. The combined technique enables the downsizing of the original PCU capacity by 25–40% and demonstrates a potential cost reduction of the PCU by approximately 30%, which translates to an installed cost reduction of ∼$125,000 per dispenser.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Hydrogen Fuel Cell Technologies Office (HFTO)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2475289

Alternate ID(s):: OSTI ID: 2369004

Journal Information:: International Journal of Hydrogen Energy, Journal Name: International Journal of Hydrogen Energy Vol. 61; ISSN 0360-3199

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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25 ENERGY STORAGE
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heavy-duty vehicle
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precooling unit

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