Liquid hydrogen boil-off modelling & cryogenic cold integration for fuel cell thermal management in aviation

Abstract

De-carbonizing aviation is necessary for a sustainable future, and using hydrogen in a fuel cell, that produces water, can greatly reduce greenhouse gas emissions. Achieving higher gravimetric energy density with hydrogen compared to conventional jet fuels, involves storing it in cryogenic liquid form. Along with it, its cryogenic temperature range not only enables its use as chemical energy storage but also as a potential heat sink. However, rapid vaporization, known as boil-off, limits the long-term storage of liquid hydrogen in fuel tanks, requiring regular venting due to self-pressurization over time. Additionally, hydrogen needs to be heated to the fuel cell’s operating temperature before being used as a reactant. Understanding these requirements, this thesis focuses on three areas: predicting the maximum boil-off rate of liquid hydrogen while charging the fuel tank using a MATLAB simulation and the boil-off rate during the flight journey using a validated software called BoilFAST to understand the feasibility of retrieving the boil-off for its integration with the fuel supply; designing a fuel supply system that integrates the boil-off gas with the vaporized liquid hydrogen supply line to the fuel cell system; and integrating the cryogenic energy of hydrogen with a ram air-cooled vapor compression refrigeration system (VCRS) based thermal management of fuel cell, with the intention of reducing its parasitic load and improving system compactness. Two methods were used for the thermal integration: VCRS involving fuel cooled heat exchangers that function as an intercooler and as a separate de-superheater before a ram air-cooled condenser; and VCRS with a separate single-phase, 52\% ethylene-glycol based serial cooling circuit with multiple fuel cooled heat exchangers (FCHX). This resulted in a significant reduction of parasitic load by 13.4% and 26% when integrated with the intercooler system and single-phase serial cooling system, respectively. The study also examined the expected additional component weight, considering the aviation sector's preference for lighter systems. The findings demonstrate that the holding time of the fuel for minimum 13 minutes after tank filling and before the start of the propulsion system unit can allow a controlled amount of boil-off gas to be integrated with the fuel supply. Utilizing cryogenic energy for thermal management can significantly enhance the system's coefficient of performance by 15.3% and 33.3% respectively. Future work should involve experiments to obtain actual boil-off rates at different ambient exposures of fuel tank, tests on sloshing effect due to turbulence during flight journeys, analysis of thermal stress effects in cryogenic heat exchangers due to high temperature gradients, and testing new compatible mixed refrigerants with improved thermal properties for optimum cryogenic heat exchange.