The present disclosure relates to fueling stations for vehicles and other devices.
Current distribution of hydrogen for the automobile and trucking markets is through hydrogen fueling stations. These stations can cost up to 2.7 million dollars per site. The hydrogen from these stations must to be pressurized to 10,000 psi or greater when using gaseous hydrogen. Other hydrogen fueling stations use liquid hydrogen which must be cooled to −423° F./−253° C. Special equipment and a great deal of energy are required to distribute either of these two forms of hydrogen.
Various embodiments are depicted in the accompanying drawings for illustrative purposes, and should in no way be interpreted as limiting the scope of the embodiments. In addition, various features of different disclosed embodiments can be combined to form additional embodiments, which are part of this disclosure.
In contrast to high pressure and/or low temperature traditionally required to store hydrogen, storing of a hydrogen carrier can be done at room temperature and at standard pressures. This increases the safety of handling hydrogen and makes the distribution of hydrogen more appealing than other methods commonly used. The cost of a single station using hydrogen stored on a hydrogen carrier is greatly reduced when compared to traditional hydrogen fuel stations. In some cases, the cost of a hydrogen carrier-type station is closer to the cost of a conventional fueling station for gasoline or diesel, thereby meeting the need for a cost-efficient and safe means of distributing hydrogen to a mass market. The stations can be built in a standard ISO (International Standards Organization) container. In some applications, the stations can be delivered to a prepared site and setup within one day. The stations described herein can also be capable of dispensing unspent hydrogen carrier and of collecting/extracting spent, used carrier fluid. This spent carrier may be rehydrogenated (e.g., many separate times) and redistributed for use.
One of the advantages realized in using the fueling stations of the present disclosure is to allow a hydrogen fuel infrastructure to be built quickly and inexpensively. In some applications, a standard, factory-built fueling station design was created based on an ISO 20-foot shipping container 103. These containers measure approximately 8×8×20 feet overall (2.4×2.4×6.1 meters). In some applications, outer trim panels or other decorative structures may be attached to or otherwise used in conjunction with the container 103 to improve the aesthetic appeal of the station 100 and/or to facilitate advertising revenue.
By using a container, an inexpensive standard platform is created that can be transported by ship, rail, barge, or truck. Using a standard design allows economies of scale and reduced site-preparation costs. Not burying the station 100 in the ground allows for far quicker permitting and set-up time. In some cases, however, burying of the station 100 may be desired. For example, burying the station 100 or some components thereof may allow for greater usable space at the installation site.
The station 100 can be designed to be completely self-contained. In addition to two flexible bladders 101, 102, with a combined liquid capacity of 5,000 US gallons, the station 100 can contain between 1 and 4 (or more) dispensing pumping stations, a battery backup system, and/or a hydrogen fuel cell to charge the batteries with or without connection to an established power grid. The needed hydrogen for the fuel cells can be generated from the Kontak Hydrogen Liquid Storage Release system similar to the systems on-board vehicles (see, e.g., U.S. Non-Provisional Ser. No. 15/826,590 filed Nov. 29, 2017, titled “INDUCTIVELY HEATED MICROCHANNEL REACTOR,” the entire disclosure of which is incorporated herein by reference). In some embodiments, one or more hydrogen fuel cells are positioned within the container 103.
The capacity of the fueling station 100 in kilograms of hydrogen will depend, of course, on the carrier molecule chosen. In one example, using the molecule designated N108, the capacity is approximately 1,700 kilograms of hydrogen when converted.
In some embodiments, it may be desirable or necessary to provide thermal protection and/or active thermal controls (heating and/or cooling) to maintain the fuel cell at peak efficiency. One solution is to utilize an onboard thermal management system positioned adjacent to or within the container. The thermal management system can run from battery power, solar power, power provided from the stored hydrogen in the bladders 101, 102, and/or from another power source.
The on-board power system can be supplemented with photovoltaic solar cells or wind turbines. Excess power can be sold into the grid if a grid connection is available and the necessary options power conditioning equipment is purchased.
In some applications, it is desirable to provide compressed hydrogen fueling to vehicles configured to operate using compressed hydrogen. As illustrated in
The compressor can be configured to compress hydrogen to a desired density and pressure for use with certain vehicles. For example, the compressor 130 can be capable of producing 860 BAR hydrogen (12,642 psi). This pressure is sufficient to allow timely filing of 700 BAR tanks and can be regulated down for 350 BAR fueling.
In some embodiments, hydrogen would be produced in the fueling station 100 and passed to the compressor. Depending on the demands for fueling, storage tanks would supplement the just-in-time compression (e.g., compression to meet contemporaneous demand) into vehicle tanks. Special fueling nozzles for compressed hydrogen could be used to facilitate compressed hydrogen vehicle fueling.
This method allows compressed hydrogen fueling without the expense of compressed gas transport. In most cases, it will allow at least a 60% reduction in the amount of free compressed hydrogen stored on site.
Because of the large power demands of compression, 3.2 kW/kg, mains power of 440 VAC at 30 A may be a requirement.
In some applications, fluid recycling is desirable. Preferably, fluid recycling systems provide storage for the “spent” or “used” fluid (e.g., carrier fluid from which at least a portion of the usable component is removed) to be recycled. One option previously used was to provide a second, separate storage tank for collection of the spent carrier. Use of a separate tank or container can present challenges, including the need for additional space and footprint for the second container, additional piping and other fluid transfer structure, and additional weight. Each of these challenges is exacerbated in mobile applications, where space and weight are major limiting factors. Previously, capturing waste product from a process for later reuse or recycle has been cumbersome due to the cost of additional ‘wasted’ space to store it onboard and the additional handling steps and cost associated with hazmat chemicals. Additionally, redundant sensor systems were often required to separately monitor the fluid levels in the spent tank and in the unspent tank.
In the present disclosure, an advantageous solution is realized—use of two tanks in a single housing. More specifically, by mounting two flexible bladders inside the same tank, overall volume and size can remain substantially constant and spent or dehydrogenated fuel can be stored in the tank for ready re-hydrogenation. For example, as fuel or other fluid from the first bladder is used, spent carrier will be returned to the ‘spent’ tank, slowly filling as the main fuel is dehydrogenated or otherwise used. Additionally, a single sensor system or configuration may be used to monitor the fluid levels in both the spent and unspent tanks to notify the user of the station 100 when refill or re-hydrogenation is advised or required.
Returning to
Preferably, adjacent bladders within the container 100 are in contact with each other over all or substantially all of their respective surfaces that face the respective adjacent bladders. For example, as illustrated, the first bladder 101 can be positioned directly above an air pressure bladder 106. In such an arrangement, all or substantially all of the bottom surface of the first bladder 101 is in contact with all or substantially all of the top surface of the adjacent air pressure bladder 106.
In some embodiments, materials and/or manufacturing methods are used to reduce friction between adjacent bladders. For example, the outer surfaces of one or more bladders may be coated or impregnated with Teflon® or some other low-friction material. In some applications, one or more inner walls of the housing 103 may be coated or otherwise treated with low-friction materials.
Maintaining contact between all or substantially all of the adjacent surfaces of the bladders can direct much or all of pressure forces between the bladders to a direction normal to the contact interfaces between the bladders. For example, in the illustrated arrangement of
In some applications, the interior of the housing 103 is open to the ambient environment. In such applications, pressure within the housing 103 is held substantially constant at the local atmospheric pressure. Preferably, the interior of the housing 103 is constructed from a rigid material and is sealed from the ambient environment and maintained at a pressure higher than the local atmospheric pressure. For example, the pressure within the housing 103 can be maintained at a level greater than both atmospheric pressure and the partial pressure of the fluids contained within the first and second bladders 101, 102. Maintaining such pressure (e.g., pressures in the range of 1-6 psi, 0-5 psi, 2-8 psi, and/or 3-15 psi) can allow the fluid within the fluid bladders 101, 102 to be maintained as a liquid, even if the fluid in the bladders 101, 102 would normally be a gas in the ambient environment.
The air pressure bladder(s) 106 can be configured to indicate the respective volumes of fluid within the first and second bladders 101, 102. For example, one or more of the air pressure bladders 106 can include an air pressure conduit (e.g., a tube or other fluid conduit) connected to a pressure sensor. Reduced pressure within an air pressure bladder 106 would indicate reduced mass within the bladders above that air pressure bladder 106. Similarly, increased pressure within an air pressure bladder 106 would indicate increased mass within the bladders above that air pressure bladder 106. In the illustrated embodiment, one air pressure bladder 106 is positioned beneath (e.g., directly beneath) the second fluid bladder 102. The other air pressure bladder 106 is positioned between the first and second fluid bladders 101, 102 in the vertical direction. In this arrangement, the relative masses of the two fluid bladders 101, 102 can be determined by measuring the difference in detected pressure within the upper and lower air pressure bladders 106. More specifically, the measured pressure in the upper air pressure bladder 106 can be used to determine the mass of fluid within the first (e.g., upper) bladder 101, which can then be subtracted from the total mass determined from the measured pressure in the lower air pressure bladder 106 to determine the mass of fluid in the second (e.g., lower) fluid bladder 102. The measured masses of the fluids within the first and second fluid bladders 101, 102 can be used to calculate the volume of fluid within each bladder. In some applications, a compressor or pump could be used to inflate or deflate one or more of the air pressure bladders 106 to adjust the internal pressure of the outer housing 103 to a desired level.
The first fluid bladder 101 can be connected to at least one tube, hose, or other fluid conduit. Similarly, the second fluid bladder 102 can be connected to one or more fluid conduits. For example, a tube can be connected to the first fluid bladder 101. The tube can facilitate fluid transfer between the first fluid bladder 101 and another component (e.g., the one or more pumping stations 104). In some embodiments, the tube can be configured to connect to a filling port, a nozzle, a compressor, a reactor, or some other component. In some embodiments, the tube is configured to connect to a hydrogen release module (HRM) configured to extract hydrogen from the fluid within the first fluid bladder. A second tube can be connected to the second fluid bladder 102. The second tube can operate with respect second fluid bladder 102 in a manner similar to or the same as the operation described above with respect to the tube connected to the first bladder. In some embodiments, the first and/or second bladders 101, 102 are attached directly to one or more of the hoses 105 of the pumping station(s) without intermediate tubes or hoses. For example, the bladders 101, 102 can include a fluid interface (e.g., a valve, nozzle, or other interface) configured to connect directly to the pumping station(s) 104 and/or hose(s) 105.
In use, the first and second bladders 101, 102 are configured to operate in conjunction with each other to maintain a constant or substantially constant cumulative volume. More specifically, as fluid is introduced to one of the bladders 101, 102 via one of the tubes, the pressure within the housing 103 is increased. Additionally, a pressure-induced force (e.g., in the vertical direction according to the orientation of the bladders in
Preferably, one or more check valves and/or other flow control devices are used to control the flow rates into and out from the bladders 101, 102, 106. In some embodiments, solenoid valves or other electronically-controlled flow devices are used to control fluid flow to and from the bladders. In some embodiments, a plurality of flow devices are controlled via local or remote hardware to coordinate and control flow of fluid through the bladders.
In a preferred application, the container 100 can be configured for use with hydrogen fuel. Specifically, one of the fluid bladders 101, 102 can be used to store unspent hydrogen fuel and the other bladder 101, 102 can be used to store spent carrier. Preferably, the lower fluid bladder (second bladder 102 in the illustrated embodiment) is preloaded with unspent fuel. Because the pressure head is higher for the fluid in the lower bladder than in the upper fluid bladder, a smaller, lighter, and/or more energy-efficient pump may be used to transfer fluid out from the lower fluid bladder to an HRM or other hydrogen-extraction apparatus. The bladders 101, 102 can be fluidly connected to the port 110 on the back side of the container 100 to facilitate initial filling and/or refilling of the bladders 101, 102.
Preferably, the nozzles 108 of the fueling station 100 are bidirectional. Using a bidirectional nozzle can permit simultaneous refueling of a vehicle and collection of spent carrier from the same vehicle, without requiring two separate nozzles and/or two separate ports.
An example nozzle 300 is illustrated in
The inner tube 309 can have a proximal outlet 310 and a distal inlet 308. In some embodiments, the tube 309 defines a continuous and/or uninterrupted flow path between the outlet 310 and inlet 308. In some embodiments, one or more check valves, solenoid valves, or other flow control structures are positioned in the flow path between the outlet 310 and the inlet 308.
All or a portion of the proximal and distal distribution chambers 302, 304 can surround portions of the inner tube 309. Such a coaxial arrangement can allow for use of smaller nozzle 300 (e.g., a smaller nozzle housing 311) when compared with a nozzle having parallel noncoaxial flow channels.
In some embodiments, nozzle 300 includes a plug, shroud, or other structure configured to selectively close one or more of the inlets and outlets of the nozzle 300. For example, the nozzle 300 can include a cap (e.g., a removable cap) configured to cover the distal end of the nozzle 300 (e.g., the inlet 308 and outlet 305). In some embodiments, the cap fits on and around the distal end of the nozzle 300 via a friction fit, a threaded fit, a bayonet fit, or other mating arrangement. In some embodiments, the nozzle 300 can include a plug 315. The plug 315 can surround at least a portion of the inner tube 309 of the nozzle 300. In some embodiments, the plug 315 is configured to selectively close the outlet 305 of the annular channel to inhibit or prevent inadvertent discharge of fuel from the outlet 305. For example, the plug 315 can have an O-ring or other sealing structure 307 at or a near a distal end of the plug 315. The sealing structure 307 can be constructed from a flexible, resilient, and/or elastomeric material. In some embodiments, the sealing structure 307 is integrally formed with the remainder of the plug 315.
The plug 315 can be biased to a closed position wherein the sealing structure 307 seals the outlet 305 of the annular channel. A spring 306 or other biasing structure can be used to bias the plug 315 to the closed position. As illustrated, the spring 306 can surround at least a portion of the inner tube 309 of the nozzle 300. Preferably, the spring 306 is isolated from the annular channel such that the spring 306 does not come into contact with spent or unspent fuel. For example, as best illustrated in
As explained in more detail below, the plug 315 can be transitioned to an opened position wherein fuel or other fluid may flow between the outlet 305 and the annular channel (e.g., the distal distribution chamber 304 of the annular channel). The proximal end of the spring 306 can abut an annular or partially annular flange or wall 317 at or near a proximal end of the nozzle 300.
As illustrated in
The nozzle 300 can be configured to mate with a specific filler neck on a vehicle, tank, hydrogen release module, or other components. Various features of the filler neck and nozzle 300 can be configured to reduce the likelihood that the nozzle 300 be mated with a vehicle that is not configured to operate using the hydrogenated fuel provided by the station 100. For example, one or both of the nozzle 300 and filler neck can include keyed features, specifically-sized openings, or other designs.
As illustrated in
The outer channel can extend between an outer housing 401 (e.g., a proximal portion 402 of the outer housing 401) of the filler neck 400 and one or more of the components of the inner channel. For example, the inlet 415 of the outer channel can be defined by the space between the proximal end of the inner tube 403 and the inner wall of the outer housing 401. The outer channel can continue along the outer wall of the inner tube 403. In some embodiments, as illustrated in
As illustrated in
While the fluid flow paths are described above using components 409 and 415 as inlets and components 410 and 412 as outlets, the opposite arrangement may be used (e.g., components 410 and 412 being outlets, while components 409 and 415 are outlets). Preferably, the vehicle in which the filler neck 400 is installed includes a cap, septum, or other cover to protect the proximal end of the filler neck 400 (e.g., the end with the inlet 415 and outlet 412) when the filler neck 400 is not in use.
As illustrated in
In the illustrated embodiment, the outer housing 311 of the nozzle 300 is sized to fit within the proximal end of the outer housing 401 of the filler neck 400. As the outer housing 311 of the nozzle 300 is moved in the distal direction with the respect to the filler neck 400, the inner tube 403 of the abuts the plug 315 of the nozzle 300. Further advancement of the nozzle 300 moves the plug 315 in the proximal direction with respect to the outlet 305 of the nozzle 300, thereby opening the outlet 305 of the outer channel of the nozzle 300. In some embodiments, longitudinal movement of the nozzle 300 with respect to the filler neck 400 is limited by abutment of the outer housing 311 of the nozzle against an internal shoulder 405 of the filler neck 400.
When mated, the inner channels of the nozzle 300 and filler neck 400 can extend coaxially with each other. The outer channels of the nozzle 300 and filler neck 400 can continue in a flow path outside of the inner channels. More specifically, flow exiting the outlet 305 of the nozzle 300 can continue along the outside surface of the tube 403 and flow to the outlet 409 in a manner consistent with that described above.
In some embodiments, the nozzle 300 and/or filler neck 400 can include one or more clips, magnets, detent structures, and/or other releasable connection structures configured to inhibit accidental disconnection between the nozzle 300 and filler neck 400 when in use. In some embodiments, one or more visual indicators (e.g., lights, displaceable components, buttons, etc.) provide confirmation to the user that the nozzle 300 and filler neck 400 are fully mated. In some embodiments, the nozzle 300 includes an outer shroud configured to collect vapors that may escape during transfer of fuel between the nozzle 300 and filler neck 400.
In some embodiments, one or both of the nozzle 300 and the filler neck 400 include (e.g., on or in the nozzle/filler neck) communication components such as near field communication (NFC) components, RFID components, Bluetooth® components, and/or other components configured to convey information to other electronic devices. Such components can be configured, for example, to communicate the type and/or grade of fuel dispensed by the nozzle 300. In some such cases, communication components on the nozzle 300 and filler neck 400 can be configured to confirm that the fuel provided by the nozzle 300 is acceptable for the vehicle being refueled. In some embodiments, communication components on the nozzle 300 and/or filler neck 400 can be configured to convey performance indicators for the fueling station 100. For example, a communication component of the nozzle 300 can be configured to convey fuel flow rate (e.g., as measured by one or flow rate sensors in one or more fuel lines, weight sensors measuring weight change rates of one or more of the bladders, and/or other sensors or instruments configured to measure fuel flow rate). In some embodiments, the communication component of the nozzle 300 can be configured to convey the quantity of unspent fuel available in one or more of the bladders of the fueling station.
Each of the fueling stations 100 may be connected to the internet. Internet connectivity can allow for processing of credit card transactions and other financial operability. Various fueling station statuses (e.g., quantify of unspent fuel, power remaining in fuel cell, etc.) can be communicated to one or more remote users via the internet or some other communications protocol. GPS or other positioning methods may be used to allow a user to observe the statuses of the stations 100 in conjunction with the geographic location of those stations.
Users of the fueling stations 100 can utilize a mobile app, website, or other visual program to observe the statuses of the various fueling stations 100 in a desired geographic area. For example, as illustrated in
From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the invention. For example, non-ISO containers may be used as containers without deviating from the overall functionality of the fueling station 100. Accordingly, the invention is not limited except as by the appended claims.
The present application claims priority to U.S. Provisional App. No. 62/677,612, filed May 29, 2018, and titled “MODULAR FUELING STATION” (Attorney Docket No.: 128913-8002.US00) the entire disclosure of which is hereby incorporated by reference herein and made part of the present disclosure. The present application is also related to co-pending U.S. Non-Provisional application Ser. No. 15/826,590 filed Nov. 29, 2017, titled “INDUCTIVELY HEATED MICROCHANNEL REACTOR” (Attorney Docket No.: 128913-8001.US01); U.S. Provisional No. (62/677,649), filed May 29, 2018, titled “MULTI FREQUENCY CONTROLLERS FOR INDUCTIVE HEATERS AND ASSOCIATED SYSTEMS AND METHODS” (Attorney Docket No. 128913-8003.US00), U.S. Provisional No. (62/677,640), filed May 29, 2018, titled “SYSTEMS FOR REMOVING HYDROGEN FROM REGENERABLE LIQUID CARRIERS AND ASSOCIATED METHODS” (Attorney Docket No. 128913-8005.US00), and U.S. Provisional No. (62/677,620), filed May 29, 2018, titled “DUAL BLADDER FUEL TANK” (Attorney Docket No. 128913-8006.US00). The entire disclosures of the above-recited related applications are hereby incorporated by reference herein and made part of the present disclosure.
Filing Document | Filing Date | Country | Kind |
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PCT/US19/34288 | 5/29/2019 | WO | 00 |
Number | Date | Country | |
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62677612 | May 2018 | US |