Thermodynamic design of hydrogen liquefaction systems with helium or neon Brayton refrigerator

•A thermodynamic study is carried out for small-scale hydrogen liquefaction.•Standard and modified Brayton cycles with helium or neon are investigated.•Helium Brayton refrigerators are recommended for efficiency and simplicity.•Detailed design is presented for the prototype development of 100 L/h liquefier. A thermodynamic study is carried out for the design of hydrogen liquefaction systems with helium (He) or neon (Ne) Brayton refrigerator. This effort is motivated by our immediate goal to develop a small-capacity (100 L/h) liquefier for domestic use in Korea. Eight different cycles are proposed and their thermodynamic performance is investigated in comparison with the existing liquefaction systems. The proposed cycles include the standard and modified versions of He Brayton refrigerators whose lowest temperature is below 20 K. The Brayton refrigerator is in direct thermal contact with the hydrogen flow at atmospheric pressure from ambient-temperature gas to cryogenic liquid. The Linde-Hampson system pre-cooled by a Ne Brayton refrigerator is also considered. Full cycle analysis is performed with the real properties of fluids to estimate the figure of merit (FOM) under an optimized operation condition. It is concluded that He Brayton refrigerators are feasible for this small-scale liquefaction, because a reasonably high efficiency can be achieved with simple and safe (low-pressure) operation. The complete cycles with He Brayton refrigerator are presented for the development of a prototype, including the ortho-to-para conversion.