Enhanced Thermofluidic Modeling and Open-Source Rigorous Simulation of Hydrogen Fueling Systems Validated with Real-World Data

The process of refueling Hydrogen Fuel Cell Electric Vehicles (HFCEVs) with compressed hydrogen gas faces two primary challenges: the temperature rise in the vehicle tank and delay in fueling speed. Since most Hydrogen Refueling Stations (HRSs) are addressing these challenges through cascade systems, there is a demand for performance evaluations of fueling systems under various HRS configurations and operating conditions. However, there is a lack of generalized and validated simulation codes, and experimental results are quite limited. In this study, we develop a model that can simulate real-world fueling processes, including the cascade system, and conduct case studies based on actual HRS configurations. By implementing a more detailed mathematical model than previous studies and simulation code for not only light-duty vehicles but also heavy-duty vehicles, the developed model accurately and extensively simulates the fueling process for various operating conditions and diverse types of vehicle tanks. The reliability of the developed model is validated using real-world data collected from operational HRSs, including extreme operating conditions. The implemented code is available as open-source and supports developing the configuration and operation guidelines of HRSs to be built forward or running now.