Thermodynamic modelling and optimization of a 35MPa hydrogen refueling station using MATLAB-Simulink

The transport sector accounts for over 20% of global CO2 emissions. Fuel Cell Electric Vehicles represent a promising solution for heavy-duty applications. Their deployment, however, depends on efficient Hydrogen Refueling Stations.This study develops a thermodynamic model of a 35 MPa hydrogen refueling station for heavy-duty vehicles in Matlab-Simulink, including storage tanks, compressor, hydrogen pre-cooler, and vehicle tanks. Dynamic models are used to analyse key parameters and to assess station performance through a parametric and a realistic analysis based on bus fleet demand.Results show that to increase number of refuelings it's necessary to increase the cascade system volume by 30% or 45%, while refueling times are between 3 and 7 min. Considering the realistic operation and a bus fleet demand, refueling time decrease to 3-4 min. Finally, the control logic for the cascade system, combined with precooling temperature of −10°C, enables safe and efficient HRS operation under variable demand conditions.