Mobile refueling with hydrogen cascade architecture, and vacuum conditioning for liquid hydrogen storage systems

A ground-based cryogenic tank system for storing hydrogen (H2) comprising:

• an inner chamber configured for storing H2 in a liquid state;
• an activated carbon bonded to an outside wall of at least the inner chamber, wherein at least the inner chamber is bake-out conditioned;
• an outer chamber having an interior volume, wherein the inner chamber is positioned within the interior volume, wherein a vacuum exists in the interior volume;
• and
• at least one non-evaporable getter (NEG) for passive pumping of the interior volume.

A method of manufacturing a ground-based cryogenic tank for storing hydrogen (H2), the method comprising:

• manufacturing an inner chamber from aluminum;
• manufacturing an outer chamber having an interior volume;
• conversion coating at least the aluminum of the inner chamber;
• bonding an activated carbon to an outside wall of the inner chamber;
• bake-out conditioning the inner and outer chambers;
• positioning the inner chamber within an interior volume of an outer chamber;
• generating a vacuum within the interior volume of the outer chamber;
• and
• passive pumping the interior volume with at least one non-evaporable getter (NEG).

A mobile storage and dispensing system for refueling hydrogen (H2)-powered vehicles, the system comprising:

• a manifold configured to receive H2, wherein the manifold has a plurality of valves;
• a compressor system having a plurality of compressor stages, wherein the compressor system is in fluid communication with at least a portion of the plurality of valves of the manifold in locations between the compressor stages;
• a booster compression stage positioned downstream of the compressor system and in fluid communication between at least two of the plurality of valves of the manifold;
• and
• a plurality of H2 storage banks positioned downstream of the compressor system and the booster compressor stage,
• wherein low-pressure H2 is pressurized by at least one of the compressor system or the booster compressor stage to a working pressure and stored within one or more of the H2 storage banks, and wherein, upon a decrease of the H2 in one or more of the H2 storage banks from the working pressure, the H2 is repressurized by the booster compressor stage.

A method of refueling hydrogen (H2)-powered vehicles with a mobile storage and dispensing system, the method comprising:

• receiving low-pressure H2 at a manifold, wherein the manifold has a plurality of valves;
• increasing a pressure of the received H2 in a compressor system having a plurality of compressor stages, wherein the compressor system is in fluid communication with at least a portion of the plurality of valves of the manifold in locations between the compressor stages;
• increasing the pressure of the received H2 from the compressor system in a booster compression stage positioned downstream of the compressor system, wherein the booster compression stage is in fluid communication between at least two of the plurality of valves of the manifold;
• and
• storing H2 pressurized to a working pressure within a plurality of H2 storage banks positioned downstream of the compressor system and the booster compressor stage,
• whereby, upon a decrease of the H2 in one or more of the H2 storage banks from the working pressure, the H2 is repressurized by the booster compressor stage.