Design and optimization of high-density cryogenic supercritical hydrogen storage systems integrating with dual mixed refrigerant cycles

To address the low density of high-pressure gaseous hydrogen and evaporation issues associated with liquid hydrogen storage, cryogenic supercritical hydrogen storage method is presented in this paper. Based on a dual parallel mixed refrigerant cycle (DPMR) and a dual cascade mixed refrigerant cycle (DCMR), the density of supercritical hydrogen product is 70.74 kg/m3, closely approaching liquid hydrogen. The processes are simulated in Aspen HYSYS, optimized by genetic algorithm for lower specific energy consumption (SEC). Thermodynamic analysis is conducted to compare with hydrogen liquefaction processes, demonstrating the feasibility and superiority of proposed process. The results show that the DPMR process has an SEC of 6.422 kWh/kgH2 and exergy efficiency of 52.66%, while DCMR is 6.872 kWh/kgH2 and 49.24%. Additionally, the inclusion of ortho-para convertors in DPMR process is investigated to further analyze the impact of heat release for ortho-para conversion. Furthermore, a techno-economic analysis is conducted on three processes, validating the economic feasibility. The study indicates that cryogenic supercritical hydrogen storage system is of great significance to the development of high-density hydrogen storage technology. The DPMR and DCMR presented in this paper can significantly improve the energy efficiency and provide valuable information for the design of high-density hydrogen storage system.