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A steady-state numerical approach for the thermo-structural analysis of a cryogenic piston pump

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The process of liquefaction of gaseous fuels, such as natural gas or hydrogen, is an essential technology that helps reduce transportation costs over long distances. Cryogenic piston pumps play a critical role in these systems, as they compress the fuel up to 700 bar before vaporization and storage in high-pressure vessels. Due to the extreme temperatures and pressures involved, the design of these machines poses a significant challenge from the thermal and structural point of view. This work presents the application of a simplified numerical approach for evaluating the thermally induced stresses and deformations through a de-coupled thermo-structural three-dimensional analysis of a prototype cryogenic piston pump. Thermal simulations of the solid domain are carried out to assess the steady-state temperature distribution of the pump. The heat transfer between the pump and cryogenic liquid is computed using three-dimensional steady-state CFD simulations of the suction and discharge phases. Heat generated by friction during the working cycle of the pump and external natural convection are calculated and imposed as a heat source in the simulations. The steady-state temperature distribution is imposed in a finite-element steady-state three-dimensional structural simulation to evaluate the combined effect of thermal loads induced by the cryogenic temperatures and loads induced by the high working pressures. Results show how the proposed methodology can assist in the design of cryogenic piston pumps by offering valuable insights into the most critical aspects of these machines.
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A steady-state numerical approach for the thermo-
structural analysis of a cryogenic piston pump
Stefano Cioni1*, Francesco Balduzzi1, Luca Romani1, Luca Sambri2, Luca
Marianetti2 and Giovanni Ferrara1




Abstract.        
             

             

             

              
              



          



1. Introduction

           
             








   


              
  

             
 
             



          
       
 





          


  


             

               
           
       


               

2. Pump Geometry

 

 

       


   



   







3. Methodology

           











            

               
Figure 1.
Figure 2.
             

           

        

 





     

  

            

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

            






              
             
               




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
 

 

               


              
               




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

                


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
 
 
    


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





               
               




Figure 3.
 󰇛󰇜
󰇛󰇜
               

 
󰇛󰇜



     
        


                

Figure 4. Sketch of components tested in structural simulations and boundary conditions. (a) Cylinder
assembly: A, valve seat ring, B, cylinder body, C, piston ring seat. (b) Piston
           
          
             
















4. Results

            






           





            
          
        



  


     

  


Figure 5. Distribution of heat transfer coefficient from the simulations of suction (a) and
discharge (b) phases.
                 

  
            

















    

    


 





Figure 6. Steady temperature distribution obtained from the thermal simulations. (a) external
temperature distribution. (b) Internal temperature distribution.
 









            



Figure 7.
Figure 8.
Conclusions
            

 




            









References
 

46
 
 

 
21
 
2385
Figure 9. (a) Radial deformation distribution of the piston. The deformations are amplified by a
factor of 62. The undeformed geometry of the piston is shown in grey. (b) radial deformation of
the cylinder.
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Article
Full-text available
Cryogenic piston pumps are commonly found in cryogenic systems to pressurize low-temperature liquefied fuels, such as liquified natural gas (LNG) or hydrogen, which are then gasified and stored in high-pressure vessels. The main challenges to be tackled in the design of these machines concern the low operating temperatures, high discharge pressures, and especially the need to avoid liquid evaporation, as this can lead to a reduction of volumetric efficiency or even to the shutdown of the pump. Two effects can cause the formation of vapor bubbles: cavitation, i.e., when the static pressure falls below the saturation value during the suction phase, and evaporation due to a temperature increase of the cryogenic liquid. In this study, a numerical analysis of a cryogenic single-piston pump is carried out. In the first part of the activity, the suction phase is studied through three-dimensional, steady-state CFD simulations. The performance of the pump in terms of pressure losses is evaluated and possible improvements to the suction geometry are identified. Then, two-phase steady-state Eulerian-Eulerian simulations are performed. The Rayleigh-Plesset model is used in order to evaluate the onset of cavitation. The minimum inlet pressure conditions that avoid cavitation are identified for two different geometries underlining the positive effect of the introduced modifications. Results show that the methodology applied in this work can lead to improvements in cryogenic pump design, reducing the static pressure losses and hence limiting the risk of cavitation.
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We have developed a hydrogen (H2) refueling solution capable of delivering precooled, compressed gaseous hydrogen for heavy duty vehicle (HDV) refueling applications. The system uses a submerged pump to deliver pressurized liquid H2 from a cryogenic storage tank to a dispensing control loop that vaporizes the liquid and adjusts the pressure and temperature of the resulting gas to enable refueling at 35 MPa and temperatures as low as −40 °C. A full-scale mobile refueler was fabricated and tested over a 6-month campaign to validate its performance. We report results from tests involving a total of 9000 kg of liquid H2 pumped and 1350 filling cycles over a range of conditions. Notably, the system was able to repeatably complete multiple, back-to-back 30 kg filling cycles in under 6 min each, in full compliance with the SAE J2601-2 standard, demonstrating its potential for rapid-throughput HDV refueling applications.
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Musashi's research work on hydrogen engines has demonstrated that, in respect of not only complete elimination of abnormal combustion such as knocking, pre-ignition and backfire peculiar to hydrogen engines but also high specific power brought by greater charging efficiency, hydrogen engines with high pressure hydrogen injection, spark ignition and LH2 pump are most practical and reasonable engine system. The pressure of injection to the combustion chamber has been increased up to 10 MPa aiming at rapid injection and good mixture formation. The leakage through the clearance between the piston and the cylinder of the pump has become greater with the increase of pressure of injection. To decrease the leakage, the clearance was made smaller (up to 2.5 μm) but it was found that the clearance was so small that the piston and the cylinder of the pump were more subject to contact with each other which caused heat to be generated due to the friction. As a result, LH2 in the pump was gasified and the piston compressed the hydrogen gas. This is called “gas pumping”, and results in disability of pumping.The authors have developed a LH2 pump whose piston has a cup-shaped cavity; the thin wall of which expands toward the cylinder wall of the pump only when the pressure rises. From our experiments it has been found that the leakage could be reduced to about a half that of the old type pump with the clearance of 2.5 could be operated. As a result, a desirable pump performance was obtained.
Conference Paper
The design of a cryogenic helium pump for circulating liquid helium in a magnet and the design of a test loop for measuring the pump performance in terms of mass flow vs pump head at various pump speeds are described. A commercial cryogenic helium pump was tested successfully. Despite flaws in the demountable connections, the piston pump itself has performed satisfactorily. A helium pump of this type is suitable for the use of flowing supercritical helium through Internally Cooled Superconductor (ICS) magnets. It has pumped supercritical helium up to 7.5 atm with a pump head up to 2.8 atm. The maximum mass flow rate obtained was about 16 g/s. Performance of the pump was degraded at lower pumping speeds. (LCL)