Proceedings International Hydrogen Energy Congress and Exhibition IHEC 2005

Istanbul, Turkey, 13-15 July 2005

Compact cryogenic valves for liquefied hydrogen fuelled cars

Dr. David Brütsch, Fridolin Holdener

WEKA AG, Schuerlistrasse 8, CH-8344 Baeretswil
d.bruetsch@weka-ag.ch

ABSTRACT
WEKA Cryogenic Components provide optimal solutions for handling of low-temperature
liquefied gases under extreme operating conditions. WEKA Cryogenic Components are generally
used in applications involving liquid and gaseous media below 20K (-253 °C). Liquid hydrogen
(LH2) has been used as fuel in space vehicles, and is now drawing attention as an alternative
energy source as well as for fuelling automobiles. Until this moment WEKA has delivered more
than 2’500 cryogenic valves (with pressures up to 600bar). About 500 valves are used in the liquid
hydrogen supply chain.
Based on the long-term experience WEKA has developed a compact valve with integrated
pneumatic actuator for extreme low temperature applications. Due to the compact design, these
valves are preferred for mobile use. The valves can handle a temperature gradient of over 250
degrees and guarantee a perfect tightness over the whole temperature range. To prevent freezing at
the warm end of the valve, WEKA designed a compound spindle of extremely low heat load, made
in composite material.
Some other highlights:
• High security through pneumatic actuator with energy less safety position
• Different actuation principles (thermodynamic, electric)
• Two energy less positions through latching principle
• Designed to weld in a vacuum insulation
• Horizontal or vertical mounting in a tank
• Adaptable to customer specification and further needs
Such valves have already been ordered by gas suppliers and/or distributors and automotive
OEM’s. These compact valves – built in LH2 tanks – are at this moment in daily use. Several
automobiles are driving with this valves; one of them has already logged more than 50,000km on
the road
Keywords: compact cryogenic valve, liquid hydrogen fuelled car, automotive tank

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1. INTRODUCTION
WEKA Cryogenic Components provide optimal solutions for handling of low-temperature
liquefied gases under extreme operating conditions. Cryogenic respectively cold comes from the
Greek word κρυοσ. Generally "cryogenic" refers to the temperature range below about 120K (-
153 °C). WEKA Cryogenic Components are generally used in applications involving liquid and
gaseous media below 20K (-253 °C).

160K – 270K
Refrigeration
Technology

50K – 150K
Industrial
Cryogenics

1.8K – 70K
Cryo-Systems
for special
applications

Figure 1: Cryogenic temperature scale

Cryogenic technology is used for cooling of superconducting solenoids and acceleration cavities in
high energy physics and in fusion research. Cryogenic pumps generate ultrahigh vacuums. Liquid
hydrogen is used as fuel for rockets and more and more as energy source. Cryogenic distillation
processes are used for the production and storage of Helium and Hydrogen as well as for Oxygen,
Nitrogen and Argon. Due to its physical properties Helium (He) in the gas, liquid or super fluid
state is the most used cooling fluid with WEKA Cryogenic Components. The normal boiling point
of Helium is 4.2K. Liquid hydrogen (LH2, normal boiling point at 20K) has been used as fuel in
space vehicles, and is now drawing attention as an alternative energy source as well as for fuelling
automobiles. Until this moment WEKA has delivered more than 2’500 cryogenic valves (with
pressures up to 600bar). About 500 valves are used in the liquid hydrogen supply chain. Also used
are WEKA Cryogenic Components with gases like Oxygen (O2, normal boiling point at 90K),
Argon (Ar, normal boiling point at 87K), Air, Nitrogen (N2, normal boiling point at 77K) and
Hydrogen (H2,) as well as for rare gases like Xenon (Xe), Krypton (Kr) and Neon (Ne).

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2. WEKA STANDARD CRYOGENIC VALVES
The design of a standard cryogenic valve is particularly intended for the employment in He- and
H2-systems. These valves have to meet specific requirements which were the base for our new
development of compact cryogenic valves.
Keeping in mind that 1W cooling capacity at 4.5K has a power demand of 200...2000W the entire
equipment (valves, connecting tubes, heat exchangers, sensors, etc.) will be placed into an
insulation vacuum with a final pressure of p < 1*10-4mbar. Reducing the cooling down time of
such a system means mass-poor design of the valves, e.g. minimized thickness of walls. Choosing
the right size of a valve may also affect the efficiency of the whole system.
Today, cryogenic systems are designed for continuous operation. Liquefaction or cooling plants
are turned off only for planned revisions. Causing high costs, the complete warming up of a plant
is avoided if possible. Therefore cryogenic valves must offer a high reliability with a minimum of
maintenance effort. E.g. for changing the seat seal or the control plug the valve stem has to be
withdrawn through the housing, in order not to destroy the vacuum insulation.
Frequently applied dimensions are from DN2 to DN200 where “DN” means diameter nominal and
the number indicates the diameter of the valve bore in "mm". Primarily the size of the valve bore
and valve travel determines the flow characteristic of the valve. A second important factor is the
size and the design of the volume after the valve bore (outlet side). Reducing the flow resistance in
a valve means minimize the pressure drop. This can be achieved by a design with sufficient space
after the bore for pressure increase. While selecting or purchasing cryogenic valves same nominal
diameters from different suppliers are compared. The very central aspect is to compare the real
valve bore and the associated Kv value (Cv = 1.16 * Kv). This will give you the best idea of the
efficiency of a valve. WEKA standard cryogenic valves have a leading position in aspect of valve
efficiency.
So far normal operating pressures for cryogenic valves are from vacuum up to 25bar or 40bar.
Beside these standard applications, WEKA has delivered also bellows sealed control valves for up
to 630bar. In the future higher pressure valves will draw more attention cause they enable smaller
and more efficient plants and applications. Generally WEKA Cryogenic Valves are available as
a) Bellows sealed valves followed by a security back-up sealing and a plugged leak test port. This
high quality sealing system guarantees the highest tightness and safety under pressure and vacuum
conditions. Preferably it will be used for low density fluids like He or H2. For high purity gases it
is also recommended to use bellows sealed valves.
b) Packing sealed valves with an elastomeric quad-ring for applications which have reduced
requirements regarding tightness e.g. for fluids like Nitrogen (N2), Air, etc. However these valves
could also be used for low density gases. Static seal to outside between valve body and bonnet and
inset respectively is made with an elastomeric o-ring joint at the warm top end of the valve.
The valve body is completely welded and manufactured from stainless steel (tubes and forged
bars). Therefore the valves have a high operational reliability in continuous service and offer high
protection against losing the insulation vacuum. Different applications require different body
patterns. Standard for cryogenic cold boxes is the angle pattern (E-pattern). In transfer lines or
pipes the globe or straight pattern is often used (see D-pattern or Z-pattern). On special request the
Y-pattern is also available.

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E-Pattern D-pattern Z-pattern Y-pattern

Figure 2: Different body patterns

The cryogenic length of a valve depends on the nominal diameter, the operating temperature and
the space available in the installation. Standard cryogenic length’s are h = 600, 875, 1000 or
1300mm. If needed, other dimensions will be manufactured between the minimum (h = 300mm)
up to max. 2000mm. Up to 1000mm the standard design is used. Considering the thermal
expansion, valves with a cryogenic length longer than 1000mm need special compensating
elements.
The wall thickness of body and inset is optimized regarding minimal heat load by thermal
conductivity and pressure and shut-off loads. For further reduction of heat loads, a thermal contact
could be brazed to the body pipe for contacting a cooling shield.
The valve seat is integrally machined into the valve body at the cold bottom end. It will be closed
by a polymeric soft seal. The cardanic stem inset design guarantee seat tightness over the full
temperature range. Some movement by thermal contraction of the piping could be compensated.
Seal heads of valves size >= DN20 are spherical flexible joined to the inset. Smaller valves have
elastically buckling spindle tubes. The seat tightness and flow control characteristic are separated
by the design and adaptable to different specifications required.

Figure 3: Flexible seal head

Guiding elements in the warm and cold part of the valve are usually made from Aluminium-
Bronze. Not by cold medium contacted areas could also consist of brass alloys. Best results
regarding seat tightness and temperature stability will show thermoplastics like PTFE, PCTFE or
PE UHMW. Also PEEK is very suitable in specific conditions. Designing the valve seat means
also consider the special characteristics of these plastics at ambient and cryogenic temperatures.
Normally are the elastomers NBR or FPM used for the O-ring seals.

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Exact tolerances of the valve bore made it possible to use the valves for both, on/off- (digital-) and
control applications. For control valves appropriate standard flow plugs with either equal-%
(1:100) or linear flow characteristics are available. Plugs with other special flow characteristics
will be calculated and produced on request. Digital valves will be equipped with a flow trim which
assures highest possible Kv value.

100

90

80
relative valve flow coefficient kv (%)

linear
70 1:10 ideal
1:10 modified to zero
60
1:20 ideal
1:20 modified to zero
50
1:50 ideal
40 1:50 modified to zero
1:100 ideal
30 1:100 modified to zero
1:1000 ideal
20

10

0
0 10 20 30 40 50 60 70 80 90 100

relative valve travel (%)

Figure 4: Different flow characteristics

Standard cryogenic valves are equipped with a vacuum weld-in flange for cold-box mounting from
the bottom side. On request we deliver valves without weld-in flange or valves with bigger flange
diameter for assembling through the top plate. In special cases valves with vacuum jacket or with
special vacuum flange assembly could be designed and manufactured.

2.1 Valve Actuators

WEKA Cryogenic Valves are normally equipped with pneumatic diaphragm actuators. Selectable
are also manual drives or electric actuators. Actuator control accessories like limit switches,
positioner, 3/2-way solenoid valves etc. could be selected according the specified valve function
(control or on/off valve).

with positioner with inductive sensors electric actuator manual drive

Figure 5: Actuator types

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The actuator size and type is derived by the nominal valve size (DN), the specified operating or
shut off pressure, the available energy (air pressure, power supply) and the plant control system.
Particularly to consider are also the specifications about actuating time, fail function in case of
energy loss and other restrictions like x-ray radiation or explosion proofed equipment.
Due to large spatial expansion of cryogenic systems the newest developments of the field bus
technology have an improved relevance for the process control. Communicating with the field
devices will be more and more important, e.g. WEKA valves are available with profibus or
foundation fieldbus interface. This opens new perspectives for the operation and maintenance of a
plant. Valves equipped with a digital electro-pneumatic position controller may receive over the
field bus new operating parameters. On the other hand, number of valve movements, travel and
actuating time could be logged. Deviations or special alarm limits could be processed by the
master control.

3. COMPACT CRYOGENIC VALVES FOR LH2 FUELLED CARS

Three years ago, an automotive OEM asked for compact valves with on/off function. Based on the
long-term experience WEKA has developed a special valve with integrated pneumatic actuator for
liquid hydrogen (LH2) application. The valves are built in a LH2 tank, where every tank needs two
or three valves. The following figure shows the basic elements of such a tank. Two containers are
separated by an insulation vacuum and super insulation carried by two suspensions. The pressure
in the tank is controlled by an electrical heater and a relief valve. Extracting hydrogen normally
happens in gaseous state; while accelerating or in other power consuming situations hydrogen will
be extracted in liquid form.

Relief valve Suspension

LH2 Level (-253°C)
Super insulation
Gaseous hydrogen
Level probe
Inner vessel
Filling line
Gas extraction

Shield

Outer vessel

Liquid extraction

Electrical heater
Filling port Cooling water WEKA Valves
heat exchanger (Shut off valves)

Figure 6: Automotive tank for LH2

Due to limited space the valves had to be very short. The actual valve design has an overall length
of 300mm. Resulting fact is, that the valve has to handle a temperature gradient of over 200
degrees over a cryogenic length of 130mm. To prevent freezing at the warm end of the valve,
WEKA designed a compound spindle of extremely low heat load, made in composite material.

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Furthermore reducing the evaporation rate is a goal of all tank manufacturers. Therefore the valve
has to guarantee a perfect tightness over the whole temperature range. On one hand the valve is
bellows sealed, on the other hand the soft-sealing head has a parabolic geometry.

Spring loaded cap

(safety position)
Pneumatic
piston actuator

Weld-in flange for

vaccuum insulation

Minimized cryogenic
length h=130mm

Housing with Z-pattern

inlet & outlet 90° rotated

Figure 7: Compact cryogenic valve for LH2

Such valves have already been ordered by gas suppliers and/or distributors and automotive
OEM’s. These compact valves – built in LH2 tanks – are at this moment in daily use. Several
automobiles are driving with this valves; one of them has already logged more than 60,000km on
the road.

3.1 Energy less safety position

The valve and in special the pneumatic actuator has an energy less safety position. In case of
energy loss a preloaded spring will move the piston in the actuator and close the valve. In this
closed position the valve is perfectly tight. Therefore only for opening a pneumatic actuation is
needed. Two energy less positions could be designed by using a latching principle. In this case
laterally arranged springs hold the valve spindle in two end positions.

3.2 actuation principles

As usually mounted on standard cryogenic valves the compact cryogenic valve has also a
pneumatic actuator. The spindle is fixed to a piston which is hold in the closed position by a
spring. On board of an automobile often the energy is available in electrical form. Therefore
concepts are needed with electrical actuation. The following figure shows a thermodynamic
principle where a noble gas is heated by electrical resistance wires. Holding the valve in the closed
position is enabled by springs. Using an electrical drive as actuating device is also a solution.
However the energy less safety position has to be designed either with spring force or with a pin.

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flow

Figure 8: thermodynamic actuation principle

3.3 integration aspects
Onboard of a car or a bus, the cryogenic valves usually are nearby the LH2 tank. From WEKA’s
point of view we do not see at the moment other insulating variants than the weld-in in a vacuum
insulation. Therefore the valves are equipped with a weld-in flange and a withdrawal inset.
Depending on space and geometric situation the valve has to be mounted either vertically or
horizontally. Mounting a cryogenic valve horizontally means prevent the liquid medium to flow to
the warm end of the valve. The existing design is adaptable to other mounting situations or
customer specific needs

4. CONCLUSION
Compact cryogenic valves have some similar aspects compared with standard cryogenic valves.
Regarding the minimized heat load, highly relevant are the design and the manufacturing of the
compound spindle. Completely welded housings guarantee a long-term stability of the vacuum
insulation. In the future producing large series of valves may change the manufacturing method of
the housings. Standards for cryogenic valve tightness in automotive area are to define. WEKA’s
values of seat tightness and the measuring method are derived from the vacuum technology and
satisfy our customers.
The design and the manufactured compact valves have been proven in everyday use. Several
automobiles are driving with this valves; one of them has already logged more than 60,000km on
the road. Future developments will continuously improve the actual design and show the
suitability for mass production.

REFERENCES
Frey, H., Haefer, R.A., Tieftemperaturtechnologie, Hrsg.: Eder, F.X., VDI Verlag GmbH,
Düsseldorf, 1981
Holdener, F., Ventile in der Kryotechnik in: DKV Tagungsbericht, 24. Jahrgang, Band 1,
Deutscher Kälte- und Klimatechnischer Verein e.V., Hamburg, 1997, pages 85 - 94
Holdener, F., Einsatz, Auslegung, Konstruktion und Fabrikation von Ventilen für die Kryotechnik,
in: Dick, S., Kecke, H.J., (Hrsg.), Industriearmaturen 2000, Vulkan Verlag GmbH, Essen,
2000, pages 44 – 53
Wutz, M., Hermann, A., Walcher, W, Theorie und Praxis der Vakuumtechnik, 4. Auflage 1988, F.
Vieweg & Sohn Verlagsgesellschaft mbH, Braunschweig, 1988