Thermal Performance Of System Research Articles

Experimental study on improving the thermal performance of isobutane refrigeration system by parameter optimization

Improvement of thermal efficiency for isobutane refrigeration system could match well with the building requirements of low-carbon, and sustainable development. The electric radiant heater (ERH) is widely used for the freeze and cold storage (FCS) system, but it has problems of high electric consumption and high freezer compartment temperature rise (FCTR) as a result of low heat-transfer efficiency under defrosting. Therefore, a novel FCS system with an additional electric radiant heater (AERH) based on the heat required for frost melted and synchronous defrosting is proposed. The defrosting consumption and the FCTR of the novel FCS system are comprehensively evaluated by a novel evaluation method. Besides, the effect of the thermal parameters (i.e., the defrosting pause temperature, the position, and electric power of the AERH) on the heat transfer characteristics are compared and optimized by the experimental method. Finally, a novel method is presented to predict the optimum thermal conditions. The results show that the optimum system thermal performance is obtained, the defrosting duration and defrosting consumption are reduced by 44.02 % and 37.03 %, and the defrosting efficiency and energy efficiency could be increased by 17.92 % and 9.96 %, respectively, as compared to the conventional FCS system. The proposed FCS system has better economic performance and heat transfer efficiency. Meanwhile, 30.54 kg of CO2 emissions could be avoided during the annual operation period, and the environmental benefits are also considerable. This study not only reaffirms the benefit of using the AERH for defrosting in the FCS system but also provides a reference for the promotion and application of efficient heat transfer technology in building refrigeration engineering.

Performance and economic study of a novel high-efficiency PEMFC vehicle thermal management system applied for cold conditions

This paper proposes three different heating management systems, sysse (self priming thermal management system), syslow (low temperature thermal management system), and syssp (split flow thermal management system), which are mainly composed of PEMFC and heat pump subsystems. Simulations were conducted to compare the comprehensive performance of these systems under cold startup and cold operating conditions, and analyzed the effect of different factors on these three system. The results show that under the influence of cell stack parameters, compared to sysse and syslow, the syssp has an average power consumption reduction of 29.95 % and 20.94 %, with a maximum power reduction of 31.46 % and 27.61 %, the average range power increases by 35.09 % and 23.58 %, with a maximum range power increase of 107.53 % and 75.57 %, the average COPPEMFC (Coefficient of Performance of heating Proton Exchange Membrane Fuel Cell) increases by 0.56 and 0.37. Under the influence of heat pump parameters, the evaporating temperature has a larger impact on the performance gains of the syssp, while condensing temperature has a greater effect on power consumption, range power, and COP variations. Compared to sysse and syslow, the syssp can recover costs as quickly as 3.12 and 3.68 years.

Numerical investigation of the saturating soil layers' effect on air temperature drops along the pipe of Earth-Air Heat Exchanger systems in heating applications

The study investigates the performance of an Earth-Air Heat Exchanger (EAHE) system, which uses underground pipes to pre-condition incoming air by leveraging the stable temperatures of the earth, thereby enhancing energy efficiency in buildings. A key challenge in heating applications is the heat loss experienced by air as it exits the pipe, which leads to a temperature drop. This study addresses this issue by exploring the impact of different soil layer configurations on reducing the outlet air temperature drop. A numerical analysis was conducted, to simulate various arrangements of soil layers to determine their effect on the outlet air temperature. The soils used include typical soil and sand-bentonite mixtures with moisture contents of 0 %, 10 %, and 20 %. The results indicate that the optimal configuration consists of two layers: an upper layer of one meter of dry typical soil and a lower layer of wet sand-bentonite soil with 20 % moisture content. This configuration yields an outlet air temperature of 20.2˚C, representing a 15.9 % increase compared to a single-layer model. This study provides novel insights by demonstrating that specific soil layer arrangements can significantly enhance the thermal performance of EAHE systems, offering a potential solution to minimize temperature drops in heating applications.

Solar energy utilization for underfloor heating system in residential buildings

In this paper, the thermal performance of a solar energy system for heating a residential building is experimentally investigated. In this system, the solar thermal energy is supplied via a flat plate solar collector that provides the heated water into a small-scale chamber, that represents the residential building. The experimental setup is installed in Jouf University campus (Latitude: 29° 47′ 1.9” N, Longitude: 40° 2′ 42.2” E) located at Al-Jouf Province, Saudi Arabia. In this experiment, the hot water supplied from solar collector is mixed with water in the storage tank, then extracted from bottom of the tank to be circulated in a copper tube loop located underneath the floor tiles of the chamber and hence increases the chamber’s air temperature. Two circulation pumps are installed in the system, one to circulate the water between solar collector and storage tank and the other to circulate the water between storage tank and chamber. Measurements of several parameters were conducted to evaluate the overall thermal efficiency of the system. The experimental results showed an average efficiency of 51 %, when operating the system for eight-hours duration in the winter season. Additionally, an economic assessment was carried out to confirm the system’s feasibility. This assessment demonstrated that the constructed system is economically feasible, with an estimated benefit-cost ratio of 1.42.

Interfacial area concentration correlation for boiling steam-water two-phase flows in annulus flow channels

The investigation of boiling two-phase flows in annulus flow channels has garnered increasing significance given its extensive utilization in various heating devices and its crucial contribution as a fundamental basis for comprehending boiling two-phase flow behavior in intricate flow channels, such as rod bundle flow channels. Accurate modeling of Interfacial Area Concentration (IAC) in boiling steam-water two-phase flows is essential for enhancing the predictive performance of the two-fluid model in simulating complex two-phase behaviors in a diverse range of practical boiling systems. The present study evaluates the predictive performance of seven representative IAC correlations using available typical experimental IAC data from boiling steam-water two-phase flows in annulus flow channels. Although some representative IAC correlations exhibit favorable predictive performance for specific experimental databases, none of the reviewed existing correlations consistently maintain acceptable predictive performance across all collected experimental data. In order to enhance the accuracy and reliability of IAC predictions under boiling flow conditions, a novel IAC correlation has been proposed grounded in physical-based considerations to effectively model the IAC contributions of small (group-1) and large (group-2) bubbles in boiling steam-water two-phase flows in annulus flow channels. The newly proposed two-group bubble IAC correlation has been validated through the examination of 303 boiling steam-water data obtained from annulus flow channels, demonstrating satisfactory predictive performance with the mean relative error of 0.216. Moreover, the applicability of the newly proposed IAC correlation to rod bundle flow channels has been evaluated using 53 boiling steam-water data taken from a 3 × 3 rod bundle flow channel, yielding a favorable prediction result with a mean relative error of 0.173. The anticipated improvement in the accuracy of predicting IAC for steam-water two-phase flows through the newly proposed correlation is expected to provide a scientific foundation for enhancing the performance and safety of thermal systems.

Performance of a high-temperature transcritical pumped thermal energy storage system based on CO2 binary mixtures

Pumped thermal energy storage is a novel energy storage technology with features of high efficiency, geographical independence and suitable for bulk capacity energy storage. As a subset of pump thermal energy storage system, the transcritical CO2 arrangements have received widespread attention due to their excellent thermodynamic performance. However, the high cost and low efficiency of heat exchange progress caused by CO2 phase transition hinder the transformation of this system from scientific theory to practical application. CO2 binary mixtures is innovatively employed as working fluid in proposed system. The temperature of mixture is variable rather than remaining constant during the evaporation and condensation progresses. R134a, R290, R600 and R601 are selected respectively to mix with CO2 to form the new working fluids. Advanced thermodynamic and economic models are established to investigate the performance of novel systems. Results indicate that the system driven by CO2/R134a with a refrigerant mass fraction of 0.15 exhibits the optimal overall performance. At the optimal point of the 10 MW/8h system, the round trip efficiency and levelized cost of storage are 66.18 % and 0.146 $/kWh, respectively. Moreover, the investigation of system performance with various energy storage capacities is put forward. It is shown that when the energy system capacity reaches 300 MW, the levelized cost of storage can be reduced to 0.122 $/kWh. To adapt to different peak and valley periods in different regions, systems with different charge and discharge times are investigated and it is found that the charge duration should better be equal to the discharge duration.

Investigation of the effects of different nanoparticle-reinforced liquids on the cooling performance of the battery thermal management system

Investigation of the effects of different nanoparticle-reinforced liquids on the cooling performance of the battery thermal management system

Effects of adding micro/nano-scale surface roughness on upward flow boiling of R-134a through annular tubes

The enhancement of heat transfer efficiency is crucial for development of high-performance thermal systems in various industrial applications. This study investigates heat transfer and pressure drop during upward saturated flow boiling of R-134a in annular tubes featuring smooth and micro/nano-scale roughened copper surfaces achieved through sandblasting and chemical etching. A high-pressure chamber with a glass side is designed to observe surface wettability and measure contact angles of R-134a on both surfaces. The annular tubes, with inner and outer diameters of 28.6 and 42 mm respectively, and a total heated length of 1000 mm, undergo varying mass flux, vapor quality, and saturation pressure within ranges of 6.73–20.19 kg m−2 s−1, 0.14–0.95, and 530–1000 kPa, alongside heat flux variations from 608 to 2432 W m−2. Results indicate that the application of micro/nano-scale roughness to copper surfaces minimally reduces the contact angle of R-134a which slightly improves its wettability. However, this modification significantly increases the heat transfer coefficient by 256 % compared to the smooth tube, albeit with an associated increase in pressure drop. Additionally, increasing mass flux and vapor quality increases both the heat transfer coefficient and pressure drop. Furthermore, higher heat flux results in a higher heat transfer coefficient with a small increase in pressure drop. Also, the experimental results are compared with some of the available correlations in the literature. The novelty and significance of this work advances our understanding of effect of surface roughness on flow boiling characteristics. Understanding these phenomena is crucial for optimizing the design and performance of heat exchangers and other thermal systems used in various industries, including refrigeration, air conditioning, and power generation.

Performance of a combined battery thermal management system with dual-layer phase change materials and air cooling technologies

Lithium-ion batteries are increasingly applied in electric vehicles, energy storage and more. In order to ensure its stable operation under different ambient temperature, an innovative battery thermal management system (BTMS) based on phase change material (PCM) has the dual-layer PCMs arrangement is proposed in this research. To prove the effectiveness of this structure, the temperature variation of lithium-ion battery 18,650 with single PCM and dual-layer PCMs arrangement is calculated and compared by numerical simulation. The findings reveal that the dual-layer PCMs arrangement proposed in this paper has better environmental adaptability at different ambient temperatures (Tamb). When the Tamb is 20 °C and the discharge rate increases from 1C to 5C, the maximum temperature (Tmax) of the battery under the dual-layer PCMs arrangement is 25.33 °C, 30.80 °C, 33.58 °C, 35.80 °C, 39.07 °C, respectively. And in response to the high ambient temperature and high discharge rate, the dual-layer PCMs layout is combined with air cooling to form a hybrid BTMS. The results show that Tmax of the hybrid BTMS is reduced by 21.5 % compared with the PCM-based BTMS when the Tamb is 40 °C and the discharge rate is 3C. The proposed hybrid BTMS with dual-layer PCMs structure controls the Tmax of the battery pack well and the temperature uniformity is also maintained within acceptable level, which has great application potential in battery thermal management.

Analysis on Rotation Timing of Dynamic Rotating Latent-Energy-Storage Envelope

The application efficiency of the Dynamic Rotating Latent-Energy-Storage Envelope (DRLESE) system is highly contingent upon dynamic rotation timings. To gain the optimal rotation timings, six different timings were examined by employing the liquid fraction, thermal storage and release, surface temperature and heat flow. The numerical heat transfer method was employed and verified an experiment. Results indicated that the optimal initial rotation occurs in the forenoon, when the inner surface temperature aligns with the sol-air temperature. Subsequently, achieving optimal secondary rotation is possible in the afternoon when the sol-air temperature equals the liquid temperature of PCM (Phase Change Material). Under these optimized initial and secondary rotation timings, the significant enhancements in thermal performance of the DRLESE system were observed. By optimizing rotation timings, indoor effective heat release can reach up to 3182.9 kJ/Day with an effectiveness percentage exceeding 99.99%, and inner surface heat flow was increased by 5.86%∼12.26%.

Interfacial area concentration correlation for boiling steam-water two-phase flows in annulus flow channels

The investigation of boiling two-phase flows in annulus flow channels has garnered increasing significance given its extensive utilization in various heating devices and its crucial contribution as a fundamental basis for comprehending boiling two-phase flow behavior in intricate flow channels, such as rod bundle flow channels. Accurate modeling of Interfacial Area Concentration (IAC) in boiling steam-water two-phase flows is essential for enhancing the predictive performance of the two-fluid model in simulating complex two-phase behaviors in a diverse range of practical boiling systems. The present study evaluates the predictive performance of seven representative IAC correlations using available typical experimental IAC data from boiling steam-water two-phase flows in annulus flow channels. Although some representative IAC correlations exhibit favorable predictive performance for specific experimental databases, none of the reviewed existing correlations consistently maintain acceptable predictive performance across all collected experimental data. In order to enhance the accuracy and reliability of IAC predictions under boiling flow conditions, a novel IAC correlation has been proposed grounded in physical-based considerations to effectively model the IAC contributions of small (group-1) and large (group-2) bubbles in boiling steam-water two-phase flows in annulus flow channels. The newly proposed two-group bubble IAC correlation has been validated through the examination of 303 boiling steam-water data obtained from annulus flow channels, demonstrating satisfactory predictive performance with the mean relative error of 0.216. Moreover, the applicability of the newly proposed IAC correlation to rod bundle flow channels has been evaluated using 53 boiling steam-water data taken from a 3 × 3 rod bundle flow channel, yielding a favorable prediction result with a mean relative error of 0.173. The anticipated improvement in the accuracy of predicting IAC for steam-water two-phase flows through the newly proposed correlation is expected to provide a scientific foundation for enhancing the performance and safety of thermal systems.

Realizing rapid cooling and latent heat recovery in the thermoelectric-based battery thermal management system at high temperatures

To realize rapid cooling of the battery at high temperatures and effective latent heat recovery from phase change materials (PCMs), a thermoelectric-based battery thermal management system (BTMS) is proposed. Additionally, a transient multiphysics numerical model is developed to predict the system's thermal performance, and the concept of the latent heat recovery rate of PCMs is introduced. Results show that the introduction of thermoelectric coolers (TECs) significantly enhances the system's efficiency in cooling the battery at high temperatures (Stage 1) and recovering PCM latent heat (Stage 2). The overall thermal performance can be further improved by utilizing PCMs with a higher mass fraction of expanded graphite (EG) or increasing the TEC input current. Moreover, after the end of Stage 2, the power supply for TECs is interrupted, and the system enters Stage 3, which only relies on PCMs to control the battery temperature. The duration of Stage 3 increases with the EG mass fraction, achieving a peak of 3830 s at an EG mass fraction of 12%. Considering the thermal performance and power consumption of the system, the optimal solution is determined as an EG mass fraction of 12% and a TEC input current of 4 A. In this situation, the required time for Stage 1 and Stage 2 is 170 s and 620 s, with the latent heat recovery rate of PCMs up to 361.94 J/kg/s. The findings will provide new insights for the development of the thermoelectric-based BTMS.

Impact of Mass Flow Rate on Thermal Behavior of PCM-Based SWH during Charging Operations

Using phase change materials in solar water heaters presents an intriguing prospect due to their notable energy density and potential for substantial thermal energy storage capacity. In the context of active-type solar water heaters, careful consideration must be given to the water flow rate as a crucial parameter. This paper investigates the thermal dynamics of active-type solar water heaters equipped with phase change materials, examining variations in mass flow rate during the charging process. Indoor experiments utilized horizontal tanks, flat plate collectors, pumps, and solar simulators. Cylindrical capsules filled with paraffin wax were employed and arranged horizontally within the tank, while K-type thermocouples were utilized to monitor water and paraffin wax temperatures. Charging procedures were executed over 160 minutes with mass flow rate adjustments. Data analysis was performed to evaluate the system's thermal performance during charging. Results indicate higher mass flow rates correspond to increased instantaneous, cumulative heat storage, and charging efficiency. The mass flow rate notably affects the thermal efficiency of solar water heater systems incorporating phase change materials.

Comprehensive performance evaluation on a transcritical CO2 ejector-expansion heat pump system

In order to reduce irreversible loss and recover expansion work for improving automotive thermal system performance, this study experimentally evaluated the performances and characteristics of a CO2 ejector-expansion (EJE) heat pump system for electric vehicles under typical cooling and heating operating modes, examined the adaptability of the EJE system with a fixed-dimension ejector, and compared the EJE system with the basic-regenerative (REG) and vapor-injection (INJ) systems in the − 30 °C to 50 °C range. The results show that the increasing electronic expansion valve (EXV) opening leads to an increasing entrainment ratio and a decreasing lift ratio in both two modes. The maximum COP is 2.00 at 35 °C/27 °C (out-cabin/in-cabin air temperature) and 1.85 at 0 °C/20 °C. The COP improvement reaches a maximum of 21.6 % and 31.0 % at the ejector design temperature of 45 °C, compared to the REG and INJ systems, respectively. However, the heating performance of the ejector designed at a high temperature significantly decreases as the ambient temperature goes down. At − 30 °C/20 °C, the EJE system performs worse with a COP degradation of 6.1 % compared to the REG system.

Performance assessment of single-sided operation in a high-temperature latent heat storage system under fault conditions during charging and discharging

As the high-temperature latent heat storage (LHS) market continues to expand, ensuring its safe and stable operation is paramount for facilitating its rapid development. In specific operational scenarios and instances of failures, large-scale integrated LHS systems may operate with either single or partial sets of heat exchange tubes. However, a notable research gap exists in the comprehensive exploration of the impact of partial operational conditions on the thermal performance of LHS systems. Consequently, this study conducted experiments involving both- and single-sided charging and discharging using a cylindrical high-temperature LHS system equipped with two sets of heat exchange tubes. To comprehend the ramifications of single-sided operation on temperature distribution across both active and inactive sides, as well as its influence on charging/discharging power and accumulated stored/released energy on the active side. The analysis of phase change material (PCM) temperature distribution revealed that single-sided charging significantly influenced the inactive side, while single-sided discharging exhibited a comparatively minor impact on the inactive side. As PCM melted during charging, temperature disparities diminished due to natural convection, while non-uniform temperature persisted in unmelted PCM. Examination of the PCM liquidus indicated that the metal heat exchange tube enhanced heat transfer on the inactive side, resulting in substantial PCM melting during charging. However, the heat transfer effect of metal heat exchange tubes during discharging was insignificant, leading to a considerable amount of liquid PCM on the inactive side after discharging. The total heat storage for both-sided charging was 1002.71 MJ, whereas, for single-sided charging using two tubes, it was 1074.42 MJ and 1000.60 MJ, respectively. Correspondingly, during discharging, the average powers were 682.74 MJ, 543.62 MJ, and 538.11 MJ, respectively. The cycle efficiency for the both-sided operation was 68.09 %, while those for single-sided operations of two tubes were 50.6 % and 53.78 %, respectively. The reduced cycle efficiencies of single-sided operations were attributed to prolonged charging and discharging durations and the presence of more liquid PCM on the inactive side after discharging.

Performance comparison of a solar parabolic trough concentrator using different shapes of linear cavity receiver

This study presents a numerical investigation of a solar Parabolic Trough Concentrator (PTC) with various Linear Cavity Receivers (LCRs). A linear trapezoidal cavity receiver was simulated and analyzed optically and thermally in the PTC system. The performance of the linear trapezoidal cavity receiver was assessed at two different angles: 25° and 55°. Optical and thermal simulations were conducted on a PTC system with a novel linear wounded tubular trapezoidal LCR. Subsequently, the optical and thermal performance of the PTC system was compared with alternative LCR shapes, namely cubical, V-shaped, trapezoidal 25°, and trapezoidal 55°. Additional contribution of the present study is to conduct energy and exergy analyses on the optimized solar PTC system employing a soybean oil-based-MXene nanofluid with varying concentrations (0 %, 0.025 %, 0.075 %, and 0.125 % weight). The findings indicate that all LCRs exhibit optimal cavity-absorbed heat flux and optical efficiency when aligned with the focal line. Moreover, the cubical and trapezoidal cavity receivers, when equipped with the ideal aperture width, demonstrate the highest and lowest performance, respectively. The most favorable exergy performance is achieved by employing the nanofluid concentration of 0.075 % weight at an inlet temperature of 55 °C at about 4 %. Also, the thermal efficiency of the solar system was calculated as about 82 % with the application of the nanofluid concentration of 0.075 % weight at an inlet temperature of 25 °C. The research findings offer valuable insights into enhancing the performance of the solar thermal system to generate more power for the implementation of the 7th development plan in Iran.

Deep learning-based inversion framework by assimilating hydrogeological and geophysical data for an enhanced geothermal system characterization and thermal performance prediction

Enhanced geothermal systems (EGS), which are developed by creating artificial fractures to enhance the permeability of deep reservoir, show their its advantage in power generation. However, due to the limited wells in deep depth, characterizing fractured geothermal reservoirs with sparse data is difficult and poses challenges for long-term thermal performance prediction. Interpreting observation data through inversion to characterize the fracture aperture and predict EGS long-term thermal performance is a hopeful scheme. Thus, a joint inversion framework, convolutional variational autoencoder-ensemble smoother with multiple data assimilation (CVAE-ESMDA), is proposed with the following aspects: (i) CVAE is trained to parameterize the high-dimensional Non-Gaussian aperture field, (ii) ESMDA is applied to integrate hydrogeological and geophysical data for aperture characterization. Based on the inversion results, the long-term performance is predicted. The normalized root mean square errors (NRMSEs) of inversion results decrease from 27.66 % to 24.52 % after multi-type data are integrated for CVAE-ESMDA. Furthermore, the NRMSEs of long-term thermal prediction of two production wells also decrease to only 2.3 % and 8.2 %. To further exhibit the advantages of CVAE-ESMDA, another joint inversion framework, principal component analysis (PCA)-ESMDA, is also compared. However, PCA is limited in addressing Non-Gaussian aperture field and its long-term thermal prediction performance is unsatisfactory.

Thermal storage performance of a novel shell-and-tube latent heat storage system: Active role of inner tube improvement and fin distribution optimization

This study presents a numerical analysis of the melting process in a shell-and-tube latent heat thermal energy storage (LHTES) system, featuring a twisted elliptical inner tube with annular fins. Utilizing paraffin as the phase change material (PCM) and water as the heat transfer fluid (HTF), this research examines the impact of varying twist degrees, fin quantity and fin distribution on the system's thermal performance during melting process. The analysis of the melting process includes complete melting time, temperature, and the contour of the solid-liquid interface. Notably, the study identifies that both fin quantity and distribution play a significant role in the melting process. The findings indicate that an optimal configuration, comprising a 720° twisted degree, 11 fins, and a base number a of 0.80, enhances the melting efficiency of the LHTES system by 156.44 % and reduces ineffective heat loss by 41.36 %. These results highlight the potential advantages of the twisted elliptical inner tube structure and propose an innovative approach with an exponentially non-uniform fin distribution, marking an advancement in the field of thermal energy storage.

Viability of an Open-Loop Heat Pump Drying System in South African Climatic Conditions

Drying agricultural produce consumes a considerable amount of energy. As an energy-efficient system, a heat pump can improve the energy efficiency of the drying process and hence reduce the energy consumption, especially in South Africa, where both sub-tropical and temperate weather conditions dominate. The objective of this research is to experimentally investigate the impacts of weather conditions on the operational conditions and thermal performance of an open-loop air-source heat pump drying system. The experimental investigation was conducted in a climate chamber where the climate conditions were simulated from −10 °C to 20 °C with an interval of 10 °C for the typical temperature range of the harvesting season in South Africa. The findings indicate that ambient temperatures have a significant impact on both the operating conditions and thermal performance of an open-loop heat pump system; the change in ambient temperatures from −10 °C to 20 °C leads to a 141.6% improvement in the suction pressure, a 214.2% increase in the discharge pressure, and 30.1% increase in the compression ratio, as well as a consequent increase of 130.6% in the refrigerant mass flow rate (from 0.0067 to 0.0155 kg/s), resulting in a corresponding increase in the coefficient of performance (COP) of the heat pump drying system by about 42.1%. Therefore, this study suggests that, while using an open-loop air-source heat pump drying system utilising R134a refrigerant is feasible in South Africa, it may be practically limited to regions with warm climates or during warmer seasons.

Numerical simulation and thermal analysis of water circulation cooling pipe of pressurized hydrogen ship-board cylinders

In this paper, a direct cooling pipe for hydrogen inside the marine hydrogen storage cylinder (HSC) was designed, and the cooling pipe was simulated and analyzed under different cooling structures and different cooling fluids using ANSYS(Fluent) 2022 R2. The simulation results show that the effect of different cooling fluids on the temperatures were nearly the same. The heat transfer coefficients, however, of various fluids were different, and the cooling temperature was also different after cooling for the same time. The cooling structures mainly affect the cooling rate of the hydrogen due to the contact area with hydrogen inside the HSC. Among the three structures investigated in this study, the cooling capacity of the spiral layout was increased by 0.85 % and 0.63 %, respectively, compared to the rectangular and wavy layout. The rectangular layout has the certain cooling effect, however, in comparison to the spiral tube structure, it has too many corners, which increases the hindering effect on the flow of cooling medium inside the tubes and affects the cooling efficiency. The wavy layout has the largest contact area, but it has the problems of uneven cooling and occupying a large amount of hydrogen storage space. Among the three structures, comprehensively speaking, the spiral layout is considered to be the optimal. The optimal performance parameters were determined by comparing the simulation results of the three layouts during cooling process with hydrogen charging being performed. The results show that the cooling pipe can achieve the hydrogen temperature to be controlled within 358 K before the hydrogen pressure in the HSC reaches 70 MPa, and the maximum temperature is 336.07 K was obtained after the completion of hydrogen filling. This paper gives technical information for optimizing the thermal performance and safety of the hydrogen fueling system.