WHEC 16 / 13-16 June 2006 – Lyon France

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, f.holdener@weka-ag.ch

ABSTRACT:
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. For further
compactness a valve block design will be developed.

KEYWORDS : compact cryogenic valve, liquid hydrogen fuelled car, cryogenic automotive tank

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 ? ? ? ? ? .
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).
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).

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.

1/6
 WHEC 16 / 13-16 June 2006 – Lyon France

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 minimal 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 because 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.

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

Figure 1: Different body pattern
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 body
pipe to contact 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.

2/6
 WHEC 16 / 13-16 June 2006 – Lyon France

Figure 2: 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 used for the O-ring seals are the elastomers NBR
or FPM.
Exact tolerances of the valve bore made it possible to use 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 3: 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.

3/6
 WHEC 16 / 13-16 June 2006 – Lyon France

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 4: Actuator types
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 the 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 5: Automotive tank for LH2

4/6
 WHEC 16 / 13-16 June 2006 – Lyon France

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.
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 6: 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 or electro-hydraulic actuation. WEKA is testing hydraulic actuation systems for cryogenic valves.
Big advantages are the compactness and the resulting actuation forces.

5/6
 WHEC 16 / 13-16 June 2006 – Lyon France

3.3 integration aspects

Onboard of a car or a bus, the cryogenic valves usually are nearby the LH2 tank. From our 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. For further compactness the valves could be
combined in one valve block. In the following picture a liquid hydrogen tank is shown with an attached valve
box. Three valves are mounted in one weld’in flange and could be mounted as one pre-manufactured unit.
The shown valves are actuated with a hydraulic fluid. Therefore the actuators could be designed very
compact.

Figure 7: Compact valve box unit attached to a tank

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

6/6