CFD Modeling of Rotational Speed Effects on Thermal Behavior and Temperature Excursion Minimization in Large Type IV Polymer Composite Hydrogen Storage Tanks

During fast-fill, large type IV polymer composite hydrogen storage tanks experience significant temperature gradients associated with both the compression of the gas and a Joule–Thomson effect that can compromise vessel integrity, significantly affecting overall safety. In order to remedy this concern, the current work proposes a novel active mixing approach in which the tank rotates, which leads to enhanced internal convective heat transfer and consequently minimizes temperature gradients. Transient CF simulations were performed using the Redlich–Kwong real-gas equation of state, capturing the high-pressure thermodynamic behavior of hydrogen precisely. The study, based on the 1000 s fast-refueling of a tank of 20.56 m3 internal volume, was carried out to assess the tangential speeds of rotation at 10, 30, and 50 rad/s, respectively. Results also show that thermal performance has a strongly nonlinear dependence on rotational speed. At 10 rad/s, a reasonably even temperature profile develops with a much lower energy cost. The most significant suppression of peak temperatures, and therefore the most efficient cooling, is seen at 30 rad/s. Nevertheless, when the rotation speed further elevates to 50 rad/s, abundant viscous dissipation heating results in an unwanted secondary temperature increase while partially counteracting the benefits brought about by improved mixing. On the whole, the results indicate that an ideal operating window more closely correlated with 30 rads/s is seen to provide the most beneficial compromise between temperature uniformity, maximum temperature limitation, and energy consumption for rapid refueling of large composite hydrogen storage systems.