Design and Optimization of High Pressure and Large Displacement Compressor Testing System for Tank Trunk Filling

Hao SHI , Lei WANG , Xiu-feng GAO , Yun LI

Science Technology and Engineering ›› 2025, Vol. 25 ›› Issue (18) : 7613 -7620.

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Science Technology and Engineering ›› 2025, Vol. 25 ›› Issue (18) : 7613-7620 DOI: 10.12404/j.issn.1671-1815.2405904
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Design and Optimization of High Pressure and Large Displacement Compressor Testing System for Tank Trunk Filling
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Abstract

The transportation via high-pressure long-tube trailers serves as a crucial method for medium-short distance transfer of flammable and explosive gases such as hydrogen and natural gas. As the core equipment in this system, the trailer filling compressor operates under continuously varying discharge pressures across wide ranges during gas loading processes. Current research and development phases face challenges in fully replicating real-world operating conditions for thermal performance testing. Addressing this requirement, this study proposes a closed-loop experimental system with gas staged recovery and continuous release functions, featuring continuous backpressure regulation capability for trailer filling compressors. The system enables the simulation of actual filling processes by creating both stable and dynamic operating conditions with wide-ranging discharge pressure variations for comprehensive compressor testing. A mathematical model of the testing system was established using zero-dimensional simulation methodology. Systematic investigations were conducted on parameter variations and operational characteristics throughout complete testing procedures, including initial pressurization, compressor startup/shutdown, and wide-range operational testing. Through optimized improvements in system configuration and component matching, critical operational constraints were achieved: gas reservoir temperatures were maintained below 85 ℃ during testing, and post-recovery system pressures were reduced below 1.5 MPa. These optimizations resulted in the development of a refined and rational testing system and methodology for trailer filling compressors, effectively addressing the technical challenges in simulating actual working conditions during compressor development phases.

Keywords

trailer filling compressor / thermal performance / testing system / zero-dimensional simulation

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Hao SHI, Lei WANG, Xiu-feng GAO, Yun LI. Design and Optimization of High Pressure and Large Displacement Compressor Testing System for Tank Trunk Filling. Science Technology and Engineering, 2025, 25(18): 7613-7620 DOI:10.12404/j.issn.1671-1815.2405904

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