In this paper, the performance of a Roots pump for hydrogen recirculation in proton exchange membrane (PEM) fuel cell system is simulated based on CFD modeling. The Roots pump is in a three-lobe configuration with helical rotors, and it is developed specifically for fuel cell systems between 60 to 110 kW. A three-dimensional model of the Roots pump is established to predict the pump performance, including the flow rate and power consumption under various operating conditions. Extensive simulations were conducted and then verified experimentally by operating with working fluids of air and helium. Based on the validated CFD model, the contents of water vapor and nitrogen in the hydrogen recirculated are taken into account to evaluate the Roots pump performance numerically according to the actual conditions of the recirculating hydrogen at the stack outlet. It is shown that the volumetric efficiency and isentropic efficiency are improved with the increase fraction of water vapor and nitrogen. It is found that the performance of the Roots pump integrated in the PEM fuel cell system is between the performance of the pump working with air and helium. Finally, correlations of volumetric efficiency and isentropic efficiency are given based on the CFD results to show the general pattern of this kind of hydrogen pump. It is believed that these equations are very helpful to the design and operation control of the PEM fuel cell system.

The temperature rises hydrogen tanks during the fast-filling process could threaten the safety of the hydrogen fuel cell vehicle. In this paper, a 2D axisymmetric model of a type III hydrogen for the bus was built to investigate the temperature evolution during the fast-filling process. A test rig was carried out to validate the numerical model with air. It was found significant temperature rise occurred during the filling process, despite the temperature of the filling air being cooled down due to the throttling effect. After verification, the 2D model of the hydrogen tank was employed to study the temperature distribution and evolution of hydrogen during the fast-filling process. Thermal stratification was observed along the axial direction of the tank. Then, the effects of filling parameters were examined, and a formula was fitted to predict the final temperature based on the simulated results. At last, an effort was paid on trying the improve the temperature distribution by increasing the injector length of the hydrogen tank. The results showed the maximal temperature and mass averaged temperature decreased by 2 K and 3.4 K with the length of the injector increased from 50 mm to 250 mm.

Hyper compressors are key facilities for producing the low-density polyethylene with discharge pressure up to 350 MPa. Such high pressure brings great challenges to the design of the hyper compressor in many aspects. In this paper, a 3D transient computational fluid dynamics (CFD) model with inlet and outlet pipelines is built to investigate the thermodynamic performance of a hyper compressor. To realize the interaction between the thermodynamic processes and the pressure pulsation through valve dynamics, the pressures across the valve surfaces were monitored to the dynamic equation of the poppet valve. Then, structured grids were generated for the flow domain inside the valve, and the entire numerical model was solved by a commercial code: ANSYS Fluent. Consequently, the p-V diagram, the valve motion and pressure pulsation could be acquired simultaneously. The results of the numerical model showed that the exponents of the expansion and compression processes were 5.12 and 13.22, which were much larger than the common compressor. The maximal pressure pulsations were 13.25% and 22.07%, which occurred in the suction and discharge chambers, respectively. Severe flutter happened during the opening process of the suction valve due to the high incompressibility of the ethylene.