The present invention relates to a method for a safe, accurate and fast operation and control of gas filling, e.g. hydrogen, from a filling station to a receiver such as a vehicle.
Several filling station vendors and research institutes have alternative filling methods, such as referred to in the next section. They most often use correlations from experimental data to generate pre-defined sequences of operation based on parameters like ambient temperature, initial vehicle pressure and cooling capacity on the station.
Limitations/problems with existing technology
However, as all of these previously known solutions are presenting different kind of disadvantages and shortcomings, the main objective of the present invention is to propose a method for the operation and control of hydrogen filling to ensure safe, fast and accurate filling of the tank volume in vehicles, for instance. The method is based on physical and thermodynamically derived relations that give a broad and reliable operational window.
According to the present invention it is provided a method for the operation and control of gas filling from a filling station to a receiver, comprising:
The main filling can comprise:
In a preferred embodiment the filling is further comprising:
Further, the estimation of filling variables can comprise:
Preferably, the initial filling can comprise:
Alternatively, the main filling can comprise:
Thus, the present invention solves the problems associated with existing technology:
Mass flow metering can be done by a mass balance, utilizing simple, reliable instrumentation such as temperature and pressure sensors, thus increasing reliability and reducing investment cost.
Now, the structure of the method according to the present invention is illustrated be means of a preferred embodiment presented the accompanying drawing, in which:
As stated above the invention is applicable in different technical fields but is hereinafter discussed by means of an embodiment with reference to vehicles.
The current method is developed for filling with or without communication with the receiver, so-called “communication fueling” (when specified information is transmitted, e.g. IR, from the receiver and verified at the station) and “non-communication fueling” (absence of receiver communication) mode, respectively.
The default mode of operation provides for communication fueling, in which the measured values of the receiver's storage pressure and temperature are utilized for controlling the filling. The fueling station controller switches to non-communication fueling in the event of break in communications. Also if there are significant deviations between the estimated parameters in the present method described hereby, and those measured and communicated from the receiver, a conservative approach should be taken or the filling should be shut down.
The following explains how to make available continuous estimates of the essential filling variables and parameters to be used in non-communication fueling.
It is essential to estimate the receiver's gas pressure during filling for enabling of continuous updates of the receiver's estimated capacity and gas temperature during filling. The following algorithm is enabling a continuous estimate of the vehicle pressure during periods of filling and periods of rest. Some alternative modes of estimation occur:
Some restrictions apply to the estimated pressure:
From the station storage tank to the receiving tank, one can imagine there are two main restrictions to flow: one control or fixed-restriction valve and one internal-receiver restriction. The internal-receiver restriction is considered as a fixed-restriction. During filling, mass flows through both these restrictions with negligible accumulation, and thus the rates through the two restrictions are the same, and one can eliminate the mass flow from the equations and get an estimate of the receiver's pressure.
According to the International standard, IEC 60534-2-1, “Industrial-process control valves—Part 2-1: Flow-capacity—Sizing equations for fluid flow under installed conditions”, the IEC valve equation is as follows:
Where N and Cv are constants. Substituting the density with proportionality to pressure and compressibility ration (ρ1∝p1/z1), this expression is simplified to:
Indexing the storage pressure with 1, the line pressure with 2 and the receivers' pressure with 3, the equations for the mass flows through the two restrictions are as follows:
In the last equation above, the expansion factor Y2 has been assumed constant and included in the constant k2. This is valid for small differences in pressure 2 and 3 (and makes the estimate of p3 below first order in p3).
By conservation of mass, the two mass flows are equal, and p3 can be expressed as function of the other pressures:
Where the pressure estimation parameter αPE(=k12/k22) is subject to tuning, and shall be a function of valve travel in the case of using a control valve.
When knowing (or estimating) an initial temperature and pressure (state 1) and a current temperature and pressure (state 2) given a known added mass, the capacity (volume) of the receiver can be estimation as follows:
The accuracy of the capacity estimate is improved by utilizing the fact that it is a specified and limited number of alternative gas tank sizes on the marked. Thus, only given discrete capacity sizes exist which are alternative solutions to the equation.
The suggested method selects the smallest capacity, being the smallest volume, fitting in the range of a smallest and largest estimate of the volume according to equation (8). The large and small estimate is obtained by calculating a minimum and maximum temperature change in the receiving gas tank as derived in the following section.
As an option, an initial estimate of the receiver's capacity can be made by filling a small, well-defined amount of gas, Δm, to the receiver and measuring the resulting change in pressure. This well-defined amount of gas can be the amount contained in a well defined enclosed volume at the filling station, as to give a first accurate estimate of the tank volume/capacity by interpreting the resulting pressure increase therein.
The isothermal and adiabatic temperatures are two extremes between which the actual receiver's gas temperature is ending up.
The case of isothermal filling is the simplest:
T
2,iso
=T
1 (9)
Where T1 is the initial gas temperature and T2 is the temperature at state 2 (intermediate or final).
To derive a case where the temperature changes, it is necessary to set up the enthalpy balance for the receiver's tank:
where hs is the (molar/mass) averaged enthalpy of the source (station tank) and index 1 and 2 refer to the initial and final state.
The adiabatic case is when no heat is exchanged with the surroundings, i.e. Q=0. Further, using the state equation pV=znRT, it is possible to eliminate n1 and n2:
The enthalpy and compressibility factor for state 2 can be approximated by linear expressions:
The partial derivatives of z and h are found from an equation of state. Inserting these approximations in the enthalpy balance above yields an explicit expression in T2:
For a direct temperature estimate one can fit an adiabatic factor, α, to relate the real gas temperature to the adiabatic temperature:
T
2
=T
1+α(T2,adi−T1) (15)
Using a band of adiabatic factors results in a band of resulting temperatures:
T
2,min
=T
1+αmin(T2,adi−T1)
T
2,max
=T
1+αmax(T2,adi−T1) (16)
The adiabatic factor is a tuning parameter; generally being dependent on filling rate, tank type etc.
The algorithm for estimating the receiver's capacity in terms of volume is thereby:
When the tank volume is determined, it is possible to estimate the density from the following equation:
The density function can be an equation of state such as the one recommended by NIST, i.e. Lemmon, E. W., Huber, M. L., Fried, D. G., Paulina, C., Standardized equation for hydrogen gas dens ties for fuel consumption applications, SAE 2006-01-0434; http://www.boulder.nist.gov/div838/Hydrogen/PDFs/Hydrogen-2006-01-0434.pdf.
Further, the temperature can be estimated as follows:
The last equation is implicit in T2 because z2 is also a function of T2. Therefore, an iterative loop must be made where z2 is updated by the previous estimate of T2. Three iterations are recommended.
Mass flow metering can be done by applying a mass balance to the filling station storage tanks. In this way one utilizing simple, reliable instrumentation such as temperature and pressure sensors, thus increasing reliability and reducing investment cost.
The amount of gas filled from a storage tank is found from a mass balance using the density function. Here index 1 and 2 are for the initial and final states respectively:
m
1
=Vρ
1, ρ1=ρ(T1,p1)
m
2
=Vρ
2, ρ2=ρ(T2,p2)
Δm=m1−m2=V(ρ1−ρ2) (20)
The temperatures are preferably measured storage gas temperatures, or estimated from ambient temperature corrected for the temperature loss as a consequence of expansion. For a multi-tank storage, a similar mass balance must be applied to each of the tanks.
The mass flow rate can be found by differentiating the mass balance equation:
The structure of the method according to the present invention is illustrated be means of a preferred embodiment presented a single accompanying drawing (FIG. 1,2).
As stated above the invention is applicable in different technical fields but is hereinafter discussed by means of an embodiment with reference to vehicles.
As already mentioned above,
The station is illustrated with a low pressure tank 1, and two separate high pressure tanks 2, 3 but, when needed, each of these tanks may be supplemented with more tanks or one of the tank types may be omitted. The low pressure tank is provided with a compressor 4 and each of high pressure tanks are having an on/off valve 5, 6. A receiver tank 14 with a check valve 13 is connected to the filling by means of a connector 12. To enable well defined initial measure and check conditions in the receiving tank 14, the filling station is provided with an enclosed volume 7 also communicating with the low and high pressure tanks 1, 2, 3. In extension of enclosed volume a filling on/off valve 8, a filling control valve 9, an optional cooler 10 are arranged in the pipe extending therefrom and is terminating in the connector 12 by means of a flexible hose 11. A filling station controller 15 is connected, not illustrated, to all instrumentation and automatic valves.
As shown in
Essential and specific elements in this invention are as follow:
Continuously updated estimates of filling control variable such as vehicle gas volume, gas pressure, gas temperature, and gas density based on fundamental physical and thermodynamic relations.
In a communication-type of filling, these estimates are used to verify the measured and communicated filling variables. In case of deviations, the filling switches to a safe mode.
The accuracy of the estimates is further improved by utilizing the fact that there is a limited alternative possible vehicle tank sizes on the marked. This ensures the best possible reproducibility accuracy with respect to state of charge (SoC) at the end of filling.
The temperature estimate is used online to control of the filling rate, enabling a fast filling. Typically, the temperature is to be controlled to a setpoint and kept there during the filling. This is the optimal filling strategy for the fastest possible filling.
An optional initial filling sequence with two small well controlled filled masses ensures an initial accurate capacity (volume) estimate of the vehicle tank.
Optionally, the method is utilizing mass balance for measuring the mass flow instead of a conventional mass flow meter.
If process data is redundant, the algorithm can execute date reconciliations such as estimating flow both from measuring the pressure drop over a restriction, from a mass balance on storage tanks, from a mass flow meter, and from a mass balance on the receiver.
Number | Date | Country | Kind |
---|---|---|---|
2009 3181 | Oct 2009 | NO | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/NO2010/000375 | 10/21/2010 | WO | 00 | 6/29/2012 |