Quantitative risk assessment of an urban hydrogen refueling station

Hydrogen is one of important energy source in the next generation of renewable energy. It has powerful strength such as no emission from CO2 for fuel, Nevertheless, many countries have difficulties to expand hydrogen infra due to high risky from hydrogen. Especially, the hydrogen refueling station which is located in urban area has congested structure and high population around, it has higher risk than conventional refueling station. This paper presents a quantitative risk assessment (QRA) of a high pressure hydrogen refueling station in an urban area with a large population and high congestion between the instruments and equipment. The results show that leaks from the tube-trailer and dispenser as well as potential explosion of the tube-trailer are the main risks. For the safety of the station operator, customers and people surrounding the refueling station, additional mitigation plans such as adding additional safety barrier system have to be implemented on the compressor and dispenser in order to prevent continuous release of hydrogen from an accident.     

A study of hydrogen leak and explosion in different regions of a hydrogen refueling station

The consequences of hydrogen leaks and explosions are predicted for the sake of the safety in hydrogen refueling stations. In this paper, the effect of wind speed on hydrogen leak and diffusion is analyzed in different regions of a hydrogen refueling station, and the influence of delayed ignition time on hydrogen explosion after an accidental hydrogen leak is further studied by numerical simulation. Results show that the effect of wind speed on the probability of hydrogen fires is distinctive in different regions of hydrogen refueling station. The size of combustible clouds in the trailer front region and the outer region increases in the low wind speed case, and the front of combustible clouds is formed in a spherical shape in the outer region, which can greatly increase the probability of hydrogen explosion. However, the high wind speed may cause an increase of the risk of accidents in the near ground region. Moreover, a non-linear correlation is shown between the rate of combustible cloud dissipation and wind speed after the hydrogen stops leaking. In addition, it is found that an increase in delayed ignition time may lead to an increase in explosion intensity, which is related with the larger high temperature area and stronger explosion overpressure. Two flame fronts and the reverse propagation of the explosion overpressure can be observed, when the delayed ignition time is larger.     

Quantitative risk assessment of a mobile hydrogen refueling station in Korea

Hydrogen infrastructure is expanding. Mobile hydrogen refueling stations are advantageous because they can be moved between locations to provide refueling. However, there are serious concerns over the risk of various accident scenarios as the refueling stations are transported. In this study, we conduct a quantitative risk assessment of a mobile hydrogen refueling station. Risks that may occur at two refueling locations and the transport path between them are analyzed. Our evaluation reveals that risks are mostly in an acceptable zone and to a lesser degree in a conditionally acceptable zone. The greatest single risk factor is an accident resulting from the rupture of the tube trailer at the refueling site. At sites with no tube trailer and during the transport, the risk is greatest from large leaks from the dispenser or compressed gas facility. The mobile hydrogen refueling station can be safely built within acceptable risk levels.     

Quantitative risk assessment on a gaseous hydrogen refueling station in Shanghai

The potential risk exposure of people for hydrogen refueling stations is often a critical factor to gain authority approval and public acceptance. Quantitative risk assessment (QRA) is often used to quantify the risk around hydrogen facilities and support the communication with authorities during the permitting process. This paper shows a case study on a gaseous hydrogen refueling station using QRA methodology. Risks to station personnel, to refueling customers and to third parties are evaluated respectively. Both individual risk measure and societal risk measure are used in risk assessment. Results show that the compressor leak is the main contributor to risks of all three parties. Elevating compressors can be considered as an effective mitigation measure to reduce occupational risks while setting enclosure around compressors cannot. Both measures are effective to reduce risks to customers. As for third parties, societal risks can be reduced to ALARP region by either elevating compressors or setting enclosure around compressors. External safety distance of compressors cannot be considerably reduced by elevation of compressors, but can significantly be reduced by setting compressor enclosure. However, safety distances of the station are not very sensitive to both mitigation measures.     

Quantitative risk assessment on 2010 Expo hydrogen station

This paper presents a QRA study on a gaseous hydrogen refueling station of 2010 World Expo. Risks to station personnel, to refueling customers and to third parties are evaluated respectively. Uncertainties that intervene in the risk analysis are also discussed. The results show that the leaks from compressors and dispensers are the main risk contributors to first party and second party risks of the Expo station, indicating that risk mitigation measures should in the first place be implemented on compressors and dispensers. For the sake of the safety of station personnel, customers, and people outside the Expo station, additional safety barrier systems must be implemented on compressors and dispensers to prevent continuous release of hydrogen from happening. With appropriate mitigation measures on compressors and dispensers, risks to all three parties of the Expo station can be reduced to the value lower than the risk acceptance criteria.     

Estimation of consequence and damage caused by an organic hydride hydrogen refueling station

Organic hydride hydrogen refueling stations are currently being developed in Japan. For these stations, we estimate the consequence and damage caused by explosions and heat radiation after a hydrogen leak, and the acute toxicity caused by the leakage and dispersion of methylcyclohexane and toluene energy carriers. First, the organic hydride hydrogen refueling station is defined, and an accident scenario for four leak sizes of hydrogen and chemical leak accidents is set. Next, simulations of the blast wave pressure and heat radiation after the hydrogen leak and of atmospheric dispersion for the evaporation after liquid methylcyclohexane and toluene leaks are performed. Probit functions or threshold values are created for each type of effects caused by the explosion, heat and the inhalation effect on humans of toluene acute toxicity. Population data for the area surrounding the station are created in a 10-m mesh. The consequence and damage are estimated for each leak size. The results show that although the explosion and chemical leak affects the area around the refueling station, the effects are small in all of the accident scenarios. In contrast, although the area of the heat effect is limited to inside the refueling station, the burn damage is large, and there is a need for conducting quantitative risk assessment.     

Multi-objective and multi-period hydrogen refueling station location problem

Creating a distribution network and establishing refueling stations arises as an important problem in order to meet the refueling needs of hydrogen fuel cell vehicles. In this study, a multi-objective and multi-period hydrogen refueling station location problem that can take into account long-term planning decisions is proposed. Firstly, single objective mathematical models are proposed for the problem by addressing the cost, risk and population convergence objectives. Afterwards, a goal programming model is proposed and the results that will arise when three objectives are taken into consideration at the same time are examined. A risk analysis approach applied for each location alternative is considered in order to handle risk concerns about the hydrogen refueling station settlement. A case study is conducted in Adana, one of the crowded cities in Turkey, to determine the long-term location network plan. Covered population, operational risk and earthquake risks are used as input of the risk analysis method. The case study results show that the goal programming model covers the area with 77 hydrogen refueling stations by different types and capacities during the years from 2020 to 2030. In addition, a computational study is carried out with different alternative scenarios (different number of consumption nodes and all parameters in the model). The computational study results show that the highest deviations from the optimal solution on the model are observed in the distances between consumption nodes and targeted service area parameters which affect about 50% of absolute deviations on average. According to results, the proposed approach selects the station location suitable for the expected changes over the years.     

Dynamic simulation for optimal hydrogen refueling method to Fuel Cell Vehicle tanks

A dynamic simulation approach to investigate an optimal hydrogen refueling method is proposed. The proposed approach simulates a transient temperature, pressure and mass flow rate of hydrogen flowing inside filling equipment in an actual station during the refueling process to an Fuel Cell Vehicle (FCV) tank. The simulation model is the same as in an actual hydrogen refueling station (HRS), and consists of a Break-Away, a hose, a nozzle, pipes and an FCV tank. Therefore, we can set actual configurations and thermal properties to the simulation model, and then simulate the temperature, pressure and mass flow rate of hydrogen passing through each position based on the supply conditions (temperature and pressure) at the Break-Away. In this study, the simulated temperature, pressure and mass flow rate are compared with the corresponding experimental data. Therefore, we show that the dynamic simulation approach can accurately obtain those values at each position during the refueling process and is an effective step in proposing the optimal refueling method.     

An advanced framework for leakage risk assessment of hydrogen refueling stations using interval-valued spherical fuzzy sets (IV-SFS)

The extensive population growth calls for substantial studies on sustainable development in urban areas. Thus, it is vital for cities to be resilient to new situations and adequately manage the changes. Investing in renewable and green energy, including high-tech hydrogen infrastructure, is crucial for sustainable economic progress and for preserving environmental quality. However, implementing new technology needs an effective and efficient risk assessment investigation to minimize the risk to an acceptable level or ALARP (As low as reasonably practicable). The present study proposes an advanced decision-making framework to manage the risk of hydrogen refueling station leakage by adopting the Bow-tie analysis and Interval-Value Spherical Fuzzy Sets to properly deal with the subjectivity of the risk assessment process. The outcomes of the case study illustrate the causality of hydrogen refueling stations' undesired events and enhance the decision-maker's thoughts about risk management under uncertainty. According to the findings, jet fire is a more likely accident in the case of liquid hydrogen leakage. Furthermore, equipment failure has been recognized as the most likely cause of hydrogen leakage. Thus, in order to maintain the reliability of liquid hydrogen refueling stations, it is crucial that decision-makers develop a trustworthy safety management system that integrates a variety of risk mitigation measures including asset management strategies.     

Addition of hydrogen refueling for fuel cell bus fleet to existing natural gas stations: A case study in Wuhan,China

Hydrogen refueling is an essential infrastructure for fuel cell vehicles, and currently, it appears to be a critical service needed to initiate the highly anticipated hydrogen economy in China. A practical selecting procedure of adding hydrogen refueling service to existing natural gas (NG) stations is proposed in this study. A case study in Wuhan, China, is established to assess the feasibility and future planning. The demand for hydrogen fuel and initial supply chain of hydrogen in Wuhan are estimated based on the deployment objective of fuel cell buses. The existing NG stations are evaluated based on 300 kg/day to determine whether they meet the hydrogen safety requirement using Google map or field investigation. The safety space requirement of the hydrogen refueling area on existing NG station is determined as 25.9 × 27.1 m². The optimal hydrogen refueling plan for fuel cell buses is calculated with multi‐objective analysis in economic, environmental, and safety aspects from the view of the hydrogen refueling supply chain. It is shown that adding hydrogen refueling stations to existing NG stations is feasible in technology, economics, regulation, and operation considerations. This study provides guidelines for building the hydrogen infrastructure for fuel cell buses at their early stage of commercial operation.     

Single-tank storage versus multi-tank cascade system in hydrogen refueling stations for fuel cell buses

Many countries in Europe are investing in fuel cell bus technology with the expected mobilization of more than 1200 buses across Europe in the following years. The scaling-up will make indispensable a more effective design and management of hydrogen refueling stations to improve the refueling phase in terms of refueling time and dispensed quantity while containing the investment and operation costs. In the present study, a previously developed dynamic lumped model of a hydrogen refueling process, developed in MATLAB, is used to analyze tank-to-tank fuel cell buses (30–40 kg_H2 at 350 bar) refueling operations comparing a single-tank storage with a multi-tank cascade system. The new-built Aalborg (DK) hydrogen refueling station serves as a case study for the cascade design. In general, a cascading refueling approach from multiple storage tanks at different pressure levels provides the opportunity for a more optimized management of the station storage, reducing the pressure differential between the refueling and refueled tanks throughout the whole refueling process, thus reducing compression energy. This study demonstrates the validity of these aspects for heavy-duty applications through the technical evaluation of the refueling time, gas heating, compression energy consumption and hydrogen utilization, filling the literature gap on cascade versus single tank refueling comparison. Furthermore, a simplified calculation of the capital and operating expenditures is conducted, denoting the cost-effectiveness of the cascade configuration under study. Finally, the effect of different pressure switching points between the storage tanks is investigated, showing that a lower medium pressure usage reduces the compression energy consumption and increases the station flexibility.     

Comparative risk assessment of liquefied and gaseous hydrogen refueling stations

Several countries are incentivizing the use of hydrogen (H₂) fuel cell vehicles, thereby increasing the number of H₂ refueling stations (HRSs), particularly in urban areas with high population density and heavy traffic. Therefore, it is necessary to assess the risks of gaseous H₂ refueling stations (GHRSs) and liquefied H₂ refueling stations (LHRSs). This study aimed to perform a quantitative risk assessment (QRA) of GHRSs and LHRSs. A comparative study is performed to enhance the decision-making of engineers in setting safety goals and defining design options. A systematic QRA approach is proposed to estimate the likelihood and consequences of hazardous events occurring at HRSs. Consequence analysis results indicate that catastrophic ruptures of tube trailer and liquid hydrogen storage tanks are the worst accidents, as they cause fires and explosions. An assessment of individual and societal risks indicates that LHRSs present a lower hazard risk than GHRSs. However, both station types require additional safety barrier devices for risk reduction, such as detachable couplings, hydrogen detection sensors, and automatic and manual emergency shutdown systems, which are required for risk acceptance.     

Optimization of hydrogen vehicle refueling via dynamic simulation

A dynamic model has been developed to analyze and optimize the thermodynamics and design of hydrogen refueling stations. The model is based on Dymola software and incorporates discrete components. Two refueling station designs were simulated and compared. The modeling results indicate that pressure loss in the vehicle's storage system is one of the main factors determining the mass flow and peak cooling requirements of the refueling process. The design of the refueling station does not influence the refueling of the vehicle when the requirements of the technical information report J2601 from Society of Automotive Engineers are met. However, by using multiple pressure stages in the tanks at the refueling station (instead of a single high-pressure tank), the total energy demand for cooling can be reduced by 12%, and the compressor power consumption can be reduced by 17%. The time between refueling is reduced by 5%, and the total amount of stored hydrogen at high pressure is reduced by 20%.     

Research and development of on-site small skid-mounted natural gas to hydrogen generator in China

Using skid-mounted natural gas to hydrogen generator in hydrogen refueling station can significantly reduce the cost of hydrogen. In 2021, China successfully built the first 250 Nm³/h on-site skid-mounted natural gas to hydrogen generator, which was successfully debug-ed in Foshan, providing hydrogen products with purity ≥99.999% for FCVs. This paper summarized the technological process and development, analyzed the risk and the safety design of skid-mounted natural gas to hydrogen generator. Several key factors affecting compactness are analyzed, including process and technical route, reforming reformer and catalyst, heat exchange network, heat exchanger and steam generation system, PSA unit and overall integrated design, etc. In addition, innovative strategies to optimize the compactness of the device are given from the aspects of process flow, reforming reformer and steam generation system.The suggestions are put forward for the development and application of on-site skid-mounted natural gas to hydrogen generator.     

加氢站定量风险分析研究

结合定量风险分析理论和加氢站的特点,从加氢站的事故场景、事故频率、事故后果、死亡概率和个人风险与社会风险5个方面进行了研究,提出了加氢站定量风险分析模型,并结合某加氢站进行了实例计算分析,计算出该加氢站量化的个人风险和社会风险,再与国内外认可的可接受风险标准进行比较,得出其风险水平是否可接受的分析结论。其量化的风险分析结论将对加氢站建设的审批和公众安全认可具有重要指导意义。     

Hydrogen refueling stations and fuel cell buses four year operational analysis under real-world conditions

Worldwide about 550 hydrogen refueling stations (HRS) were in operation in 2021, of which 38% were in Europe. With their number expected to grow even further, the collection and investigation of real-world station operative data are fundamental to tracking their activity in terms of safety issues, performances, maintenance, reliability, and energy use. This paper analyses the parameters that characterize the refueling of 350 bar fuel cell buses (FCB) in five HRS within the 3Emotion project. The HRS are characterized by different refueling capacities, hydrogen supply schemes, storage volumes and pressures, and operational strategies. The FCB operate over various duty cycles circulating on urban and extra-urban routes. From data logs provided by the operators, a dataset of four years of operation has been created. The results show a similar hydrogen amount per fill distribution but quite different refueling times among the stations. The average daily mass per bus and refueling time are around 14.62 kg and 10.28 min. About 50% of the total amount of hydrogen is dispensed overnight, and the refueling events per bus are typically every 24 h. On average, the buses' time spent in service is 10 h per day. The hydrogen consumption is approximately 7 kg/100 km, a rather effective result reached by the technology. The station utilization is below 30% for all sites, the buses availability hardly exceeds 80%.     

Analysis of thermodynamic processes involving hydrogen

There is a need to explore potential hazard scenarios associated with several specific thermodynamic processes involving the storage and use of hydrogen subjected to thermal exposures. A potential real-life scenario is the heating of a hydrogen storage vessel abroad a hydrogen-powered vehicle in an automobile fire or in an accident at a refueling station. The effect of thermal exposures on these thermodynamic processes has been examined using the National Institute of Standards and Technology (NIST) REFPROP, Reference Fluid Thermodynamic and Transport Properties, database. The thermodynamic processes considered are isochoric (constant density) heating, isenthalpic expansion, and isentropic expansion. In addition, isochoric heating followed by either an isenthalpic or isentropic expansion process is also discussed. The initial fill density of a hydrogen system has a significant effect on the subsequent thermodynamic processes. From a standpoint of fire safety, a hydrogen system subjected to thermal exposure or preheating before an isenthalpic expansion would potentially increase the risk of fire, especially when the exposure temperature is very close to the hydrogen autoignition temperature.     

Numerical investigation of the vortex tube performance in novel precooling methods in the hydrogen fueling station

In the present study, the potential of integrating a Ranque-Hilsch vortex tube (RHVT) in the precooling process for refueling high-pressure hydrogen vehicles in hydrogen refueling stations is investigated. In this regard, two novel precooling processes integrating a vortex tube are proposed to significantly reduce the capital expenditure and operating costs in hydrogen fueling stations. Then a numerical study of the RHVT performance is carried out for a high-pressure hydrogen flow to validate the feasibility of the proposed processes. Obtained results from the numerical simulation show that the energy separation effect also exists in the RHVT with hydrogen flow at the pressure level of tens of megapascals. Moreover, it is found that the energy separation performance of the RHVT improves as the pressure ratio increases. In other words, the temperature drop of the cold exit of RHVT decreases as the pressure ratio decreases in the refueling process, which just matches the slowing-down temperature rise during the cylinder charge. Based on the obtained results, it is concluded that the integration of a RHVT into the precooling process has potential in the hydrogen fueling station.     

Development of a Hydrogen Refueling Station Design Tool

In the last couple of decades, there has been a growing concern in what effects fossil fuels are having on the environment, resulting in governments and governing organizations issuing stringent emission standards in an effort to curve their environmental damage. To meet these new standards, the transportation industry has been conducting research into alternative fuels, such as hydrogen, but one critical problem utilizing hydrogen is that there is almost no infrastructure. A network of hydrogen refueling stations similar to modern gasoline stations will be required to be constructed to meet future demand. The hydrogen refueling station model was created to aid in designing hydrogen facilities, thus accelerating their development while reducing design cost. A model was created using Simulink consisting of an electrolyzer that generates hydrogen, a compressor, numerous storage tanks, a dispensing unit that transfers hydrogen, and a vehicle component that consumes hydrogen fuel. The model was validated using data from existing hydrogen refueling stations, and the data obtained from testing the previous version of the hydrogen refueling station model to determine model accuracy and if the model has improved. The model has demonstrated that it can produce reasonable results for a station's performance and has improved compared to the previous version.