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Research on rapid refueling of Type-IV hydrogen storage tanks for hydrogen-powered heavy-duty commercial vehicles

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  • Lv, Hong
  • Su, Ying
  • Huang, Gangqi
  • Zhang, Qianyi
  • Zhang, Cunman

Abstract

The significant temperature fluctuations during the rapid compression of hydrogen can cause irreversible damage to hydrogen storage tanks. This poses a major challenge for the advancement of hydrogen-powered heavy-duty vehicles where refueling protocols remain underdeveloped. Therefore, a thorough analysis of the temperature variations of hydrogen storage tanks on heavy-duty vehicles during refueling is crucial for ensuring their safe operation. Referring to the refueling protocol for light-duty vehicles (SAE J2601), a three-dimensional computational fluid dynamics model is established to examine the impact of refueling categories, pre-cooling temperatures, and hydrogen incident angles on the temperature rise of a 210 L Type-IV hydrogen storage tank. The results indicate that SAE J2601 can also ensure the safe refueling of heavy-duty vehicles and serve as a reference for refining their refueling protocols. The pre-cooling temperature of 233 K is the optimal choice for heavy-duty commercial vehicles, as it ensures safe and rapid hydrogen refueling within 4 min. The −25° refueling is suitable for heavy-duty commercial vehicles, which improves the temperature distribution inside the tanks, leading to a reduction of 2.6 K in the final maximum hydrogen temperature. This research provides theoretical support for optimizing refueling protocols and the design and installation of valves for heavy-duty vehicles, which facilitates the development of fuel cell vehicles.

Suggested Citation

  • Lv, Hong & Su, Ying & Huang, Gangqi & Zhang, Qianyi & Zhang, Cunman, 2025. "Research on rapid refueling of Type-IV hydrogen storage tanks for hydrogen-powered heavy-duty commercial vehicles," Renewable Energy, Elsevier, vol. 253(C).
    • Handle: RePEc:eee:renene:v:253:y:2025:i:c:s0960148125013357
    DOI: 10.1016/j.renene.2025.123673
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    References listed on IDEAS

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    1. Yin, Bifeng & Qiu, Hao & Dong, Fei & Wang, Zhao & Jia, Hekun & Xie, Xuan, 2025. "Study on the pressurization liquid hydrogen supply characteristics in hydrogen fuel cell vehicles," Energy, Elsevier, vol. 338(C).

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