World Applied Sciences Journal 5 (2): 143-149, 2008

ISSN 1818-4952
IDOSI Publications, 2008

Corresponding Author: Mahmood Farzaneh-Gord, The Faculty of Mechanical Engineering,
Shahrood University of Technology, Shahrood, Iran
143
Thermodynamics Analysis of Cascade Reserviors Filling Process
of Natural Gas Vehicle Cylinders

1
Mahmood Farzaneh-Gord,
1
Shahram Hashemi and
2
Ahmad Farzaneh-Kord

1
The Faculty of Mechanical Engineering, Shahrood University of Technology, Shahrood, Iran
2
Department of Physics, Tarbiat Moallem University of Sabzevar, Sabzeva, Iran

Abstract: The accurate modeling of the fast-fill dynamics occurring in Compressed Natural Gas (CNG) fueled
vehicle storage cylinders is a complex process and to date those dynamics have not been thoroughly
studied. Here, based on first law of thermodynamics, conversation of mass and thermodynamics properties
table a numerical method has been developed to study fast filling process of natural gas vehicles (NGV)
cylinder. The model has been applied for commonly cascade group of three reservoir tanks. The results
indicated that there was a temperature rise in order 40 K or more during charging process. The results also
indicated that ambient temperature has big effect on filling process and final NGV cylinder conditions.

Key words: Compressed natural gas CNG cylinder Fast filling process

INTRODUCTION

Compressed natural gas is used as a clean
alternative to other automobile fuels such as gasoline
(petrol) and diesel. The natural gas (CNG) fueled vehicle
storage cylinders encountered a rise in storage gas
cylinder temperature (in the range of 40 K or more)
during the fast filling due to complex compression and
mixing processes. This temperature rise reduces the
density of the gas in the cylinder, resulting in an under
filled cylinder, relative to its rated specification. If
this temperature rise is not compensated for in
the fueling station dispenser, by transiently over-
pressurizing the tank, the vehicle user will experience
a reduced driving range.
The on-board storage capacity of natural gas
vehicles (NGVs) is a critical issue to the wide spread
marketing of these alternate fuelled vehicles. CNG is
dispensed to an NGV through a process known as the
fast fill process, since it is completed in less than five
minutes. Underfilling of NGV cylinders, during fast fill
charging operations, can occur at fuelling stations, at
ambient temperatures greater than 30C. The resulting
reduced driving range of the vehicle is a serious
obstacle which the gas industry is striving to overcome,
without resorting to unnecessarily high fuelling station
pressures, or by applying extensive over-pressurization
of the cylinder during the fuelling operation.
Undercharged storage cylinders are a result of the
elevated temperature which occurs in the NGV storage
cylinder, due to compression and other processes which
have not, to the author's knowledge, been studied,
analyzed and documented to date.
There have been limited researches in the filed of
current study in literatures. Kountz et al. [1] were first
who modeled fast filling process of natural gas storage
cylinder based on first law of thermodynamics. They
develop a computer program to model fast filling
process for a single reservoir. Kountz et al. [3-5], have
also developed a natural gas dispenser control
algorithm that insures complete filling of NGV cylinders
under a fast fill scenario. The researches are also under
way to model fast filling of hydrogen-based fuelling
infrastructure including [6, 7]. Newhouse et al. [8] have
studied fast filling of hydrogen cylinder using number
of experiments. They reported a high temperature
increase in the cylinder during the process.
A few experimental studies were also carried
out to study fast filling of natural gas cylinder
including [9, 10]. Shiply [10] concluded that
ambient temperature change can have an affect on
the fast fill process. He also concluded that, the test
cylinder was under-filled every time it was rapidly
recharged.
World Appl. Sci. J., 5 (2): 143-149, 2008

144



Fig. 1: NGV filling station-schematic

Farzaneh et al. [11] have also modelled fast filling
process. They developed a computer programme based
on Peng-Robinson state equation for single reservoir.
They investigated effects of ambient temperature and
initial cylinder pressure on final cylinder conditions.
The number of natural gas fuel based vehicles in
Iran growing rapidly recently due to government policy.
Most of owners of those vehicles have reported
under-filling charge compared to rated conditions. To
understand fast filling process and study effect of
ambient temperature, a computer programme has been
developed based on first law of thermodynamics,
conversation of mass and thermodynamics properties
table of the gas in this study. This enables us to study
effects of various parameters on dynamics change in the
NGV cylinder. The fast fill process was assumed to be
quasi-static process and the natural gas presumed to be
purely Methane.

CNG FILLING STATION

Figure 1 shows a typical CNG filling station. Gas
from the distribution pipeline, usually low pressure at
<4bar (0.4MPa) or possibly medium pressure (16 bar),
is compressed using a large multi-stage compressor into
a cascade storage system. This system is maintained
at a pressure higher than that in the vehicles on-board
storage so that gas flows to the vehicle under
differential pressure. Typically, the cascade storage will
operate in range of 205 bar to 250 bar, while the
vehicles maximum onboard cylinder pressure is
200bar. In order to make the utilization of the
compressor and buffer storage more efficient, fast fill
CNG stations usually operate using a three-stage
cascade storage system.

COMPRESSED NATURAL GAS CYLINDERS

The natural gas cylinders have various design
types based on materials of construction used. Design
types include Type 1, which are all-metal, Type 2, which
have a metal liner and hoop wrapped composite
reinforcement, Type 3, which have a metal liner and a
full wrapped composite reinforcement and Type 4,
which have a non-metallic liner and a full wrapped
composite reinforcement. Metal containers and liners
are typically steel or aluminium. Composite
reinforcements are typically carbon or glass fibbers in
an epoxy resin matrix. CNG cylinders are designed for a
specified nominal service pressure at a specified
temperature essentially a specified density (kg/m
3
) of
fuel. This will result in a given mass of natural gas
stored in the fuel container. The actual pressure in the
fuel container will vary from the nominal service
pressure as the temperature of the fuel in the container
varies. Fuelling stations normally fill the cylinder up
World Appl. Sci. J., 5 (2): 143-149, 2008

145



Fig. 2: Dimensions of a typical CNG cylinder

125% of nominal service pressure to avoid under
charging but this highly depends to ambient
temperature.
The common CNG cylinder type in Iran is Type 1.
They have same inside diameter with various heights
depending to their volume. Figure 1 shows dimensions
of a typical CNG cylinder.

CHEMICAL COMPOSITIONS OF NATURAL GAS

Natural gas composition (mixture) varies with
location, climate and other factors. The gas is refined
before flowing into the pipe lines. Table 1 shows an
experimental analysis of typical natural gas composition
which flows in Iran pipe lines according to the
Khangiran refinery official website [12]. It can be
realised that the most of compositions occupied very
low percentage. By knowing that Methane is occupied
about 99% of the gas, For the sake of simplicity it is
assumed that Methane is the only substance in the
Natural gas.

MATHEMATICAL MODELING

Governing equations: In this study to model the fast
filling process and develop a mathematical method, the
NGV cylinder is considered as a thermodynamics open
system which goes through a quasi-steady process.

Table 1: Experimental analysis of natural gas composition the
Khangiran refinery (the Khangiran refinery official
website [12])
Chemical Experimental analysis
Component formula (mole fraction %)
Carbon dioxide CO
2
0.055
Nitrogen N
2
0.428
Methane CH
4
98.640
Ethane C
2
H
6
0.593
Propane C
3
H
8
0.065
Iso butane C
4
H
10
0.015
n-Butane C
4
H
10
0.034
Iso-Pentane C
5
H
12
0.026
+C
6
+C
6
0.125
Total = 100%

The continuity and first law of thermodynamics has
been applied to the cylinder to find 2 thermodynamics
properties.
Considering the onboard NGV cylinder as a control
volume and knowing it has only 1 inlet, the continuity
(conservation of mass) equation may be written as
follow:


c
i
dm
m
dt
& (1)

In equation 1,
i
m& is inlet mass flow rate and can be
calculated by considering an isentropic expansion
through an orifice. Applying gas dynamics laws:

1
1 1 2
c r c
i d r orifice
r r r
p 2 p p
m C A ( ) ( )( ) 1 ( )
p 1 p


1

1 ' ;

1 ]
&

1 c
r
p 2
if ( )
p 1

+
(2)

1
2( 1)
i d r r orifice
2
m C p A
1
+

_


+
,
&

1 c
r
p 2
if ( )
p 1

>
+
(3)

In equations 2, 3 C
d
is discharge coefficient of
the orifice.
World Appl. Sci. J., 5 (2): 143-149, 2008

146

The First laws of thermodynamics for a control
volume in general form can be written as follow:

2
cv i i i i
2 2
e e e e cv cv
Q m(h V/ 2 gz)
m(h V /2 gz) d/dt[m(u V /2 gz)] W
+ + +
+ + + + + +

&
&
&
&
(4)

The work term is zero in the filling process and
the change in potential and kinetic energy can be
neglected. For simplicity heat transfer through the
cylinder walls into environment is not considered. By
applying the above assumptions, the equation 4 can
be rewritten as follow:

2
cv i i
d(mu) /dt m( h V /2) + & (5)

Considering stagnation enthalpy as h
r
= h
i
+ V
i
2
/2
which is actually equal to enthalpy of the reservoir
tanks, t he equation 5 is now as follow

c c
c c i r
dm du
u m m h
dt dt
+ & (6)

Combining equation 6 & 1, the following equation
can be easily driven:

c
c i c i r
du
u m m m h
dt
+ & & (7)

NUMERICAL PROCEDURE

In theory, it should be possible to calculate all
thermodynamics properties by knowing two
independent properties. The numerical procedure starts
using equation 2&3 to calculate inlet mass flow rate.
The differential equations 1 and 6 are solved using
Rung-Kuta forth order method to obtain internal energy
(u) and mass (m
c
) in the next time step. Knowing total

mass and volume of the cylinder, specific volume (v)
can be calculated. Now by knowing two independent
thermodynamics properties (v,u), other thermodynamic
properties can be calculated by using Methane
properties table provided by [13]. Solutions end
when the NGV cylinder pressure reaches a user-input
pressure (200 bar) level.

RESULTS AND DISCUSSTION

Here, the NGV cylinder has been considered
adiabatic as a result the characteristics of the orifice, will
not affect the end temperature state in the cylinder. The
orifice diameter and the cylinder volume were
considered to be 1 mm and 67 Liters as in [1]
respectively. To study the effect of ambient
temperature, initial temperature of NGV cylinder and
reservoir tanks are set to the ambient temperature.
The results have been presented for commonly used
cascade group of three as shown in Fig. 3. It worth also
pointed out that no previous work has been detected in
literature to model cascade system.

Cascade reservoirs: In this section, the results are
presented for commonly used cascade group of three as
shown in Fig. 3. The results presented here are unique
and no similar results have been presented in lit erature.
Figure 4 and 5 show effects of initial cylinder and
reservoir tank temperature on dynamic pressure and
temperature profiles of NGV cylinder respectively,
during filling process. Note from Fig. 4, there is no dip in
temperature profile in early filling time however there are
two dips in temperature profile which occurs when
supply tank change. This behaviour could be discussed
as: the Joule-Thompson cooling effect is not high
enough in early stage of the filling process and wouldn't
be able to overcome conversion of supply enthalpy
energy to cylinder internal energy. When the supply


Fig. 3: A schematic diagram of cascade reservoirs
World Appl. Sci. J., 5 (2): 143-149, 2008

147

280
290
300
310
320
330
340
350
360
370
380
0 100 200 300 400 500 600
Time (seconds)
T
e
m
p
e
r
a
t
u
r
e

(
K
)
Ti=280
Ti=290 K
Ti=300


Fig. 4: Effect of initial (ambient) temperature on dynamic temperature profile (cascade system)

0.0E+00
5.0E+06
1.0E+07
1.5E+07
2.0E+07
2.5E+07
0 100 200 300 400 500 600
Time (seconds)
P
r
e
s
s
u
r
e

(
P
a
)
Ti=280
Ti=290 K
Ti=300


Fig. 5: Effect of initial (ambient) temperature on dynamic pressure profile (cascade system)

0.0E+00
1.0E+00
2.0E+00
3.0E+00
4.0E+00
5.0E+00
6.0E+00
7.0E+00
8.0E+00
9.0E+00
0 100 200 300 400 500 600
Time (seconds)
c
y
l
i
n
d
e
r

m
a
s
s


(
k
g
)
Ti=280
Ti=290 K
Ti=300


Fig. 6: Effect of initial (ambient) temperature on the amount of charged gas (cascade system)

World Appl. Sci. J., 5 (2): 143-149, 2008

148

480
490
500
510
520
530
540
280 290 300 310 320
Initial temperature (K)
C
h
a
r
g
i
n
g

t
i
m
e

(
s
e
)
310
320
330
340
350
360
370
380
390
400
410
F
i
n
a
l

c
y
l
i
n
d
e
r

t
e
m
p
e
r
a
t
u
r
e

(
K
)
Charging time
Final cylider Temperature (K)


Fig. 7: Effect of initial (ambient) temperature on charging time and the final cylinder temperature (cascade system)

Rated mass value =10.16 Kg
0.6
0.65
0.7
0.75
0.8
0.85
0.9
0.95
1
280 290 300 310 320
Initial temperature (K)
F
i
l
l

r
a
t
i
o
6
6.5
7
7.5
8
8.5
9
9.5
10
F
i
n
a
l

c
y
l
i
n
d
e
r

m
a
s
s

(
k
g
)
Fill ratio
Final cylider mass (kg)


Fig. 8: Effect of initial (ambient) temperature on fill ratio and the amount of charged gas (cascade system)

system switches to higher pressure reservoir tank, the
higher Joule-Thompson cooling effect with help of low
temperature inlet gas, cause small dips in temperature
profile. Note from Fig. 4, rise in temperature only occur
when the NGV cylinder is connected to lowest pressure
reservoir tank and temperature profile is nearly
monotonic otherwise. Note, discontinuity in pressure
profile in Fig. 5 is due to switching to another reservoir
tank.
Figure 6 shows effects of initial cylinder and
reservoir tank temperature on amount of inlet gas.
It can be seen that at early time of filling, initial
temperature has little effect on dynamics pressure
profile. It can be also realized that low and
medium reservoir tanks supply about 25% of charged
mass and high pressure reservoir tank supply the
rest (50%).
The effect of initial (ambient) temperature on
charging time and final onboard NGV cylinder
temperature is shown in Fig. 7. Note from this figure, as
initial temperature increases, charging time decrease and
final temperature increases.
The effect of initial (ambient) temperature on fill
ratio and final mass of charged gas is shown in Fig. 8.
Note form this figure, as initial temperature increases, fill
ratio and the final mass of charged gas decreases.

CONCLUSION

In this study a numerical method has been
developed based on first law of thermodynamics,
conservation of mass and thermodynamic properties
of methane to simulate fast filling process of NGV
cylinder. Based on the method a computer program
World Appl. Sci. J., 5 (2): 143-149, 2008

149

has been built to study effect of ambient temperature
and initial NGV cylinder pressure. The model has been
applied for single reservoir tank and commonly cascade
group of three. The results indicated that there is a
temperature rise in order 40 K or more during charging
process. This would cause under-filled the NGV cylinder
and reduce driving range of the NGV. The results also
indicated that ambient temperature has big effect on
filling process and final NGV cylinder conditions. As
ambient temperature rise, the fill ratio and amount of
charged gas drop which cause low driving range as a
result, filling the NGV during night probably more
efficient than during the day especially during summer.

ACKNOWLEDGEMENT

This study has been supported by Shahrood
University of Technology funds.

Nomenclature

A Area (m
2
)
C
d
Orifice discharge coefficient
c
p
, c
v
Constant pressure
&volume specific heats (kj/kg K)
g Gravitational acceleration (m/s
2
)
h Specific enthalpy (kj/kg)
m
g
Mass flow rate (kg/s)
M Molecular weight (kg/kmol)
P Pressure (bar or Pa)
Q
g
Heat transfer rate (KW)
T Temperature (K or
o
C)
U Internal energy (kj/kg)
v Specific volume (m
3
/kg)
V Velocity (m/s)
W Actual work (kj/kg)
W
g
Actual work rate (KW or MW)
z Height (m)
+ C
6
All hydrocarbon compounds with more
than 5 carbon in their chemical formula
Density (kg/m
3
)

Subscript
c NGV cylinder
r Reservoir tank
i Initial or inlet condition

REFERENCES

1. Kountz, K., 1994, Modeling The Fast Fill Process in
Natural Gas Vehicle Storage Cylinders. American
Chemical Society Paper at 207th National ACS
Meeting, March 1994.
2. Kountz, K., W. Liss and C. Blazek, 1998. A New
Natural Gas Dispenser Control System. Paper at
1998 International Gas Research Conference, San
Diego, November 3, 1998.
3. Kountz, K., W. Liss and C. Blazek, 1998. Method
and Apparatus For Dispensing Compressed Natural
Gas. U.S. Patent 5: 752, 552.
4. Kountz, K., W. Liss and C. Blazek, 1998. Automated
Process and System For Dispensing Compressed
Natural Gas. U.S. Patent 5: 810, 058.
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NGV Fueling Station and Dispenser Control
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2003. Modeling and Testing of Fast-Fill Control
Algorithms for Hydrogen Fueling. National
Hydrogen Association Meeting.
8. Newhouse, N.L. and W.E. Liss, 1999. Fast Filling of
NGV Fuel Containers. SAE paper 1999-01-3739.
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Measurement, Approval and Verification of CNG
Dispensers. NWML KT11 Report.
10. Shipley, E., 2002. Study of Natural Gas Vehicles
(NGV) during the fast fills process. Thesis for
Master of Science, 2002. College of Engineering and
Mineral Resources at West Virginia University.
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Magrebi and M. Dorafshan, 2007. 2007. The Effect
of Initial Conditions on Filling Process of CNG
Cylinders. The second International conference on
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Abu Dhabi, UAE.
12. Khangiran refinery official website,
http://khangiran.com/pages/Products.htm.
13. National Institute of Standards and Technology
website, available at http://webbook.nist.gov/chem
istry/fluid/.