Hydrogen gas dispensing systems and methods

• US 10,236,522 B2
• Filed: 01/17/2018
• Issued: 03/19/2019
• Est. Priority Date: 01/17/2017
• Status: Active Grant

• Current Assignee: Ivys, Inc.
• Original Assignee: Ivys, Inc.
• Inventors: O'Brien, Christopher John, Pollica, Darryl Edward
• Primary Examiner(s): Maust, Timothy L
• Assistant Examiner(s): Kelly, Timothy P.
• Application Number:
  US15/873,775
• Publication Number:
  US 20180205102A1
• Time in Patent Office: 426 Days
• CPC Class Codes: C01B 2203/0465 Composition of the impurity
• CPC Class Codes: C01B 2203/0495 the impurity being water
• CPC Class Codes: C01B 3/042 Decomposition of water
• CPC Class Codes: C01B 3/50 Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification C01B3/14 takes precedence
• CPC Class Codes: F17C 13/025 having the pressure as the parameter
• CPC Class Codes: F17C 13/026 having the temperature as the parameter
• CPC Class Codes: F17C 2205/0111 Boxes
• CPC Class Codes: F17C 2205/0176 with ventilation
• CPC Class Codes: F17C 2221/012 Hydrogen
• CPC Class Codes: F17C 2223/0123 gaseous, e.g. CNG, GNC
• CPC Class Codes: F17C 2223/033 Small pressure, e.g. for liquefied gas
• CPC Class Codes: F17C 2225/0123 gaseous, e.g. CNG, GNC
• CPC Class Codes: F17C 2225/036 Very high pressure, i.e. above 80 bars
• CPC Class Codes: F17C 2227/0157 Compressors
• CPC Class Codes: F17C 2227/0164 with specified compressor type, e.g. piston or impulsive type
• CPC Class Codes: F17C 2227/043 by pressure cascade
• CPC Class Codes: F17C 2250/01 Intermediate tanks
• CPC Class Codes: F17C 2250/032 using computers
• CPC Class Codes: F17C 2250/043 Pressure
• CPC Class Codes: F17C 2250/0439 Temperature
• CPC Class Codes: F17C 2250/0452 : Concentration of a product
• CPC Class Codes: F17C 2250/0626 : Pressure
• CPC Class Codes: F17C 2265/065 : for refueling vehicle fuel tanks
• CPC Class Codes: F17C 2270/0139 : Fuel stations
• CPC Class Codes: F17C 2270/0184 : Fuel cells
• CPC Class Codes: F17C 2270/0763 : Fuel cells
• CPC Class Codes: F17C 5/007 : for individual gas tanks or containers, e.g. in vehicles filling with liquid fuel not under pressure, B60S5/02, B67D7/00
• CPC Class Codes: F17C 5/06 : for filling with compressed gases
• CPC Class Codes: F17C 7/00 : Methods or apparatus for discharging liquefied, solidified, or compressed gases from pressure vessels, not covered by another subclass
• CPC Class Codes: H01M 2250/20 : Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2250/40 : Combination of fuel cells with other energy production systems
• CPC Class Codes: H01M 8/04089 : of gaseous reactants
• CPC Class Codes: H01M 8/04201 : Reactant storage and supply, e.g. means for feeding, pipes
• CPC Class Codes: H01M 8/04373 : of auxiliary devices, e.g. reformers, compressors, burners
• CPC Class Codes: H01M 8/04425 : at auxiliary devices, e.g. reformers, compressors, burners
• CPC Class Codes: H01M 8/0444 : Concentration; Density H01M8/04492 takes precedence
• CPC Class Codes: H01M 8/04686 : of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/0656 : by electrochemical means H01M8/065 takes precedence
• CPC Class Codes: Y02E 60/32 : Hydrogen storage
• CPC Class Codes: Y02E 60/36 : Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

According to at least one aspect, a hydrogen gas dispensing system is provided. The hydrogen gas dispensing system includes a source configured to provide a hydrogen gas, a storage device configured to store the hydrogen gas up to a first pressure level, a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level, and a compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser. According to at least one aspect, the dispensing system comprises an input power port configured to receive input power and an output power port configured to deliver output power derived from the input power to charge an electric vehicle.

Claims

1. A hydrogen gas dispensing system comprising:

a source configured to provide a hydrogen gas;

a storage device configured to store the hydrogen gas up to a first pressure level;

a fire retardant material that at least partially encloses the storage device;

a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level; and

a compressor fluidly coupled to the source, the storage device, and the dispenser, the compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser.

2. The hydrogen gas dispensing system of claim 1, further comprising a controller configured to detect a storage pressure level of the storage device when a vehicle is coupled to the hydrogen gas dispensing system via the dispenser, the controller further configured to:

cause hydrogen gas to flow from the storage device to a fuel tank of the vehicle via the dispenser when the storage pressure level is greater than a threshold pressure level; and

cause hydrogen gas from the storage device to be compressed by the compressor before being dispensed to the fuel tank of the vehicle via the dispenser when the storage pressure level is less than the threshold pressure level.

3. The hydrogen gas dispensing system of claim 2, wherein the controller is configured to detect a vehicle pressure level of the fuel tank of the vehicle coupled to the hydrogen gas dispensing system via the dispenser, and wherein the threshold pressure level is relative to the vehicle pressure level.

4. The hydrogen gas dispensing system of claim 3, wherein the threshold pressure level is substantially the vehicle pressure level of the fuel tank.

5. The hydrogen gas dispensing system of claim 1, wherein the source comprises an external source of hydrogen gas.

6. The hydrogen gas dispensing system of claim 1, wherein the first pressure level is greater than or equal to approximately 5,000 and less than or equal to approximately 8,000 pounds per square inch (PSI) and the second pressure level is greater than or equal to approximately 8,000 PSI and less than or equal to approximately 12,000 PSI.

7. The hydrogen gas dispensing system of claim 6, wherein the first pressure level is approximately 6,000 pounds per square inch (PSI) and the second pressure level is approximately 10,000 PSI.

8. The hydrogen gas dispensing system of claim 1, wherein the storage device comprises a plurality of storage tanks.

9. The hydrogen gas dispensing system of claim 1, wherein the storage device is configured to store no more than approximately 10 kilograms of hydrogen gas.

10. The hydrogen gas dispensing system of claim 1, wherein the source comprises an electrolyzer configured to receive water and produce the hydrogen gas using the water.

11. The hydrogen gas dispensing system of claim 10, further comprising a hydrogen gas purifier fluidly coupled between the electrolyzer and the compressor, the hydrogen gas purifier being configured to remove at least some oxygen and/or at least some water from the hydrogen gas produced by the electrolyzer.

12. The hydrogen gas dispensing system of claim 10, further comprising:

an enclosure encasing at least the storage device and comprising an air vent; and

an air circulation device disposed in the enclosure and configured to provide ventilation for the enclosure.

13. The hydrogen gas dispensing system of claim 12, wherein the air circulation device comprises at least one fan arranged to force air from inside the enclosure to an external environment through the air vent.

14. A hydrogen gas dispensing system comprising:

a source configured to provide a hydrogen gas, the source comprising an electrolyzer configured to receive water and produce the hydrogen gas using the water;

a storage device configured to store the hydrogen gas up to a first pressure level;

a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level; and

a compressor fluidly coupled to the source, the storage device, and the dispenser, the compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser;

an enclosure encasing at least the storage device and comprising an air vent;

an air circulation device disposed in the enclosure and configured to provide ventilation for the enclosure;

a hydrogen gas sensor disposed in the enclosure and configured to detect hydrogen gas in the enclosure; and

a circuit communicatively coupled to the hydrogen gas sensor and configured to shut down at least one component of the hydrogen gas dispensing system when a hydrogen gas concentration detected by the hydrogen gas sensor exceeds a threshold.

15. A hydrogen gas dispensing system comprising:

a source configured to provide a hydrogen gas, the source comprising an electrolyzer configured to receive water and produce the hydrogen gas using the water;

a storage device configured to store the hydrogen gas up to a first pressure level;

a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level; and

a compressor fluidly coupled to the source, the storage device, and the dispenser, the compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser;

an enclosure encasing at least the storage device and comprising an air vent;

an air circulation device disposed in the enclosure and configured to provide ventilation for the enclosure;

a pressure sensor disposed in the enclosure and configured to measure a change in air pressure caused by air being forced through the air vent; and

a circuit communicatively coupled to the air pressure sensor and configured to shut down at least one component of the hydrogen gas dispensing system when an air pressure level detected by the air pressure sensor indicates an issue with air circulation.

16. A hydrogen gas dispensing system comprising:

a source configured to provide a hydrogen gas, the source comprising an electrolyzer configured to receive water and produce the hydrogen gas using the water;

a storage device configured to store the hydrogen gas up to a first pressure level;

a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level; and

a compressor fluidly coupled to the source, the storage device, and the dispenser, the compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser;

an enclosure encasing at least the storage device and comprising an air vent;

an air circulation device disposed in the enclosure and configured to provide ventilation for the enclosure;

a temperature sensor disposed in the enclosure and configured to measure a temperature of air in the enclosure; and

a circuit communicatively coupled to the temperature sensor and configured to shut down at least one component of the hydrogen gas dispensing system when a temperature level detected by the temperature sensor exceeds a threshold.

17. A hydrogen gas dispensing system comprising:

a source configured to provide a hydrogen gas, the source comprising an electrolyzer configured to receive water and produce the hydrogen gas using the water;

a storage device configured to store the hydrogen gas up to a first pressure level;

a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level; and

a compressor fluidly coupled to the source, the storage device, and the dispenser, the compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser;

an enclosure encasing at least the storage device and comprising an air vent;

an air circulation device disposed in the enclosure and configured to provide ventilation for the enclosure;

a heater disposed in the enclosure;

a temperature sensor disposed in the enclosure and configured to measure a temperature of air in the enclosure; and

a circuit communicatively coupled to the temperature sensor and the heater, the circuit being configured to control operation of the heater based on a temperature level detected by the temperature sensor.

18. A hydrogen gas dispensing system comprising:

a source configured to provide a hydrogen gas, the source comprising an electrolyzer configured to receive water and produce the hydrogen gas using the water;

a storage device configured to store the hydrogen gas up to a first pressure level;

a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level; and

a compressor fluidly coupled to the source, the storage device, and the dispenser, the compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser;

an enclosure encasing at least the storage device and comprising an air vent; and

an air circulation device disposed in the enclosure and configured to provide ventilation for the enclosure,

wherein the enclosure comprises;

a first compartment having at least the storage device disposed therein;

a second compartment having at least the electrolyzer disposed therein; and

a fire retardant material disposed between the first compartment and the second compartment.

19. A hydrogen gas dispensing system comprising:

a source configured to provide a hydrogen gas, the source comprising an electrolyzer configured to receive water and produce the hydrogen gas using the water;

a storage device configured to store the hydrogen gas up to a first pressure level;

a dispenser configured to dispense the hydrogen gas up to a second pressure level that is higher than the first pressure level; and

a compressor fluidly coupled to the source, the storage device, and the dispenser, the compressor configured to compress the hydrogen gas from the source up to the first pressure level for storage in the storage device and configured to compress the hydrogen gas from the storage device up to the second pressure level for dispensing via the dispenser;

an enclosure encasing at least the storage device and comprising an air vent; and

an air circulation device disposed in the enclosure and configured to provide ventilation for the enclosure;

a safety system for controlling powering and depowering components of the hydrogen gas dispensing system, the safety system comprising;

the air circulation device;

a pressure sensor disposed in the enclosure and configured to measure a change in air pressure to confirm correct operation of the air circulation device;

a hydrogen gas sensor disposed in the enclosure and configured to detect hydrogen gas in the enclosure;

a temperature sensor disposed in the enclosure and configured to measure a temperature of air in the enclosure; and

a safety controller coupled to the pressure sensor, the hydrogen gas sensor and the temperature sensor and configured to provide power to components of the hydrogen gas dispensing system, wherein the safety controller is configured to power and depower components of the hydrogen gas dispensing system based, at least in part, on indications received from the pressure sensor, the hydrogen gas sensor and the temperature sensor.

20. The hydrogen gas dispensing system of claim 19, wherein upon power up of the hydrogen gas dispensing system, the safety controller engages the air circulation device, the pressure sensor, the hydrogen gas sensor and the temperature sensor and provides operational power to other components of the hydrogen gas dispensing system only when the safety system confirms safe operation.

21. The hydrogen gas dispensing system of claim 19, wherein the safety controller is configured to power down the hydrogen gas dispensing system if any of the pressure sensor, hydrogen gas sensor and/or temperature sensor signal unsafe operating conditions.

22. The hydrogen gas dispensing system of claim 1, wherein the hydrogen gas dispensing system is configured to provide a visual indication of a fill level of the storage device.

23. The hydrogen gas dispensing system of claim 22, further comprising:

a lighting system configured to provide light in a selected one of a plurality of colors based on a control signal; and

a circuit coupled to the lighting system and configured to generate the control signal based on the fill level of the storage device.

24. The hydrogen gas dispensing system of claim 14, wherein the hydrogen gas dispensing system is configured to provide a visual indication of a fill level of the storage device.