The simulation and analysis of leakage and explosion at a renewable hydrogen refuelling station

The number of hydrogen refuelling stations (HRSs) is steadily growing worldwide. In China, the first renewable hydrogen refuelling station has been built in Dalian for nearly 3 years. FLACS software based on computational fluid dynamics approach is used in this paper for simulation and analysis on the leakage and explosion of hydrogen storage system in this renewable hydrogen refuelling station. The effects of wind speed, leakage direction and wind direction on the consequences of the accident are analyzed. The harmful area, lethal area, the farthest harmful distance and the longest lethal distance in explosion accident of different accident scenarios are calculated. Harmful areas after explosion of different equipments in hydrogen storage system are compared. The results show that leakage accident of the 90 MPa hydrogen storage tank cause the greatest harm in hydrogen explosion. The farthest harmful distance caused by explosion is 35.7 m and the farthest lethal distance is 18.8 m in case of the same direction of wind and leakage. Moreover, it is recommended that the hydrogen tube trailer should not be parked in the hydrogen refuelling station when the amount of hydrogen is sufficient.     

Ignited releases of liquid hydrogen: Safety considerations of thermal and overpressure effects

If the 'Hydrogen Economy' is to progress, more hydrogen fuelling stations are required. In the short term and in the absence of a hydrogen distribution network, these fuelling stations will have to be supplied by liquid hydrogen (LH2) road tankers. Such a development will increase the number of tanker offloading operations significantly and these may need to be performed in close proximity to the general public.The aim of this work was to determine the hazards and severity of a realistic ignited spill of LH2 focussing on; flammability limits of an LH2 vapour cloud, flame speeds through an LH2 vapour cloud and subsequent radiative heat levels after ignition. The experimental findings presented are split into three phenomena; jet-fires in high and low wind conditions, 'burn-back' of ignited clouds and secondary explosions7 post 'burn-back'. An attempt was made to estimate the magnitude of an explosion that occurred during one of the releases. The resulting data were used to propose safety distances for LH2 offloading facilities which will help to update and develop guidance for codes and standards.     

Safety studies on high-pressure hydrogen vehicle refuelling stations: Releases into a simulated high-pressure dispensing area

If the general public is to use hydrogen as a vehicle fuel, customers must be able to handle hydrogen with the same degree of confidence, and with comparable risk, as conventional liquid and gaseous fuels. The hazards associated with jet releases from leaks in a vehicle-refuelling environment must be considered if hydrogen is stored and used as a high-pressure gas since a jet release in a confined or congested area can create an explosion hazard. As there was insufficient knowledge of the explosion hazards, a study was initiated to gain a better understanding of the potential explosion hazard consequences associated with high-pressure leaks from hydrogen vehicle refuelling systems. This paper describes the experiments with a dummy vehicle and dispenser units to represent refuelling station congestion. Experiments with ignition of premixed 5.4 m × 6.0 m × 2.5 m hydrogen–air clouds and hydrogen jet releases up to 40 MPa (400 bar) pressure are described. The results are discussed in terms of the conditions leading to the greatest overpressures and overall conclusions are made from these.     

Dynamic planning and energy management strategy of integrated charging and hydrogen refueling at highway energy supply stations considering on-site green hydrogen production

The layout of electric vehicles charging stations and hydrogen refueling stations (HRSs) is more and more necessary with the development of electric vehicles (EVs) and progress in hydrogen energy storage technology. Due to the high costs of HRSs and the low demand for hydrogen, it is difficult for independent HRSs to make a profit. This study focuses on the dynamic planning of energy supply stations on highways in the medium and long term, considering the growth of EV charging demand and the change in the proportion of hydrogen fuel cell vehicles (HFCVs). Based on the perspective of renewable energy generators (REGs), this study seeks the dynamic optimal configuration and comprehensive benefits of adding HRS and battery to existing EVCS considering the travel rules of new energy vehicles (NEVs). The results show that (1) It is profitable for REGs to invest in HRSs; (2) The economy of investment in batteries by REGs depends on the source-load matching. It is feasible only when the output of renewable energy is difficult to meet the demand. (3) The business model of REGs producing hydrogen on-site and supplying both electricity and hydrogen is feasible.     

Improved safety by crossanalyzing quantitative risk assessment of hydrogen refueling stations

With the goal of building 310 hydrogen refueling stations (HRSs) in Korea by 2022, restrictions, such as location restrictions and separation distances, are being eased, so developing ways to improve technology and safety. As HRSs contain major facilities such as compressors, storage tanks, dispenser, and priority control panels, and a leakage could result in a large fire or explosion caused by an ignition source. To perform quantitative risk assessment, programs, namely, Hy-KoRAM and Phast/Safeti were used in this study. It could determine the damage range and effect on radiant heat and flame length, as well as personal and societal risks, using these programs. The crossanalysis of the two programs also improves the facility's safety and the reliability of the results.     

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.     

Effects of congestion and confining walls on turbulent deflagrations in a hydrogen storage facility-part 1: Experimental study

If the general public is to use hydrogen as a vehicle fuel, customers must be able to handle hydrogen with the same degree of confidence, and with comparable risk, as conventional liquid and gaseous fuels. Since hydrogen is stored and used as a high-pressure gas, a jet release in a confined or congested area can create an explosion hazard. Therefore, hazards associated with jet releases from leaks in a vehicle-refuelling environment must be considered. As there was insufficient knowledge of the explosion hazards, a study was initiated to gain a better understanding of the potential explosion hazard consequences associated with high-pressure leaks from hydrogen vehicle refuelling systems. Our first paper [1] describes the release and subsequent ignition of a high-pressure hydrogen jet in a simulated dispensing area of a hydrogen vehicle refuelling station. In the present paper, an array of dummy storage cylinders with confining walls (to represent isolation from the forecourt area) was used to represent high-pressure hydrogen cylinder storage congestion. Experiments with ignition of premixed 5.4 m × 6.0 m × 2.5 m hydrogen-air clouds and hydrogen jet releases up to 40 MPa pressures were performed. The results are presented and discussed in relation to the conditions giving the highest overpressures. We concluded from the study that the ignition of a jet release gives much higher local overpressure than in the case of ignition of a homogeneous mixture inside the cylinder storage congestion area. The modelling of these results will be presented in Part 2 of this paper.     

Liquid hydrogen releases show dense gas behavior

The number of maritime initiatives with hydrogen as alternative fuel is increasing. While most of the early projects aim at using compressed hydrogen the use of liquid hydrogen (LH2) is more practical and is expected to become more attractive for implementation on larger vessels due to more efficient storage, bunkering and handling of the fuel. In the industry there seems to be some confusion regarding the behavior of LH2 releases, in particular whether a release into air will behave like a dense gas or a buoyant gas. The understanding of this aspect is critical to optimize design with regard to safety. This article will explain the expected behavior of LH2 releases and discuss expected hazard distances from LH2 releases relative to gaseous hydrogen releases and LNG. Some other safety concerns of LH2, like indoor releases, releases from vent masts, potential BLEVEs and RPTs are also discussed. The article explains why a higher safety standard may be required when designing hydrogen fueled vessels than for existing LNG fueled vessels.     

燃料电池船舶舱内氢气泄漏爆炸的数值模拟研究

以燃料电池客船“Water-Go-Round”号为对象,利用FLUENT软件模拟燃料电池客船舱内管道发生氢气泄漏并引发爆炸的情况,研究不同舱室氢气点火爆炸事故的影响规律。结果表明：可燃氢气云被点燃后,爆炸超压波自点火位置向四周迅速传播,点火位置对超压波的分布影响较大;控制舱爆炸时,超压强度最大,对船体超压危害最大;乘客舱爆炸强度最小,但超压中心分布在乘客舱,超压对乘客造成的危害最大;船舶舱室燃烧火焰温度主要由可燃氢气云的分布决定,燃料电池舱的火焰衰减趋势基本相同;乘客舱受到的高温危害较低,船艏舱无燃烧火焰的高温危害。     

Tube-trailer consolidation strategy for reducing hydrogen refueling station costs

The rollout of hydrogen fuel cell electric vehicles (FCEVs) requires the initial deployment of an adequate network of hydrogen refueling stations (HRSs). Such deployment has proven to be challenging because of the high initial capital investment, the risk associated with such an investment, and the underutilization of HRSs in early FCEV markets. Because the compression system at an HRS represents about half of the station's initial capital cost, novel concepts that would reduce the cost of compression are needed. Argonne National Laboratory with support from the U.S. Department of Energy's (DOE) Fuel Cell Technologies Office (FCTO) has evaluated the potential for delivering hydrogen in high-pressure tube-trailers as a way of reducing HRS compression and capital costs. This paper describes a consolidation strategy for a high-pressure (250-bar) tube-trailer capable of reducing the compression cost at an HRS by about 60% and the station's initial capital investment by about 40%. The consolidation of tube-trailers at pressures higher than 250 bar (e.g., 500 bar) can offer even greater HRS cost-reduction benefits. For a typical hourly fueling-demand profile and for a given compression capacity, consolidating hydrogen within the pressure vessels of a tube-trailer can triple the station's capacity for fueling FCEVs. The high-pressure tube-trailer consolidation concept could play a major role in enabling the early, widespread deployment of HRSs because it lowers the required HRS capital investment and distributes the investment risk among the market segments of hydrogen production, delivery, and refueling.     

Study on leakage and explosion consequence for hydrogen blended natural gas in urban distribution networks

It appears to be the most economical means of transporting large quantities of hydrogen over great distances by the existing natural gas pipeline network. However, the leakage and diffusion behavior of urban hydrogen blended natural gas and the evolution law of explosion characteristics are still unclear. In this work, a Computational Fluid Dynamics three-dimensional simulation model of semi-confined space in urban streets is developed to study the diffusion process and explosion characteristics of hydrogen-blended natural gas. The influence mechanism of hydrogen blending ratio and ambient wind speed on the consequences of explosion accident is analyzed. And the dangerous area with different environmental wind effects is determined through comparative analysis based on the most dangerous scenarios. Results indicate that the traffic flow changes the diffusion path of the jet, the flammable gas cloud forms a complex profile in many obstacles, high congestion level lead to more serious explosion accidents. Wind effect keeps the flammable gas cloud near the vehicle flow, the narrow gaps between the vehicles aggravate the expansion of the flammable gas cloud. When the wind direction is consistent with the leakage direction, hydrogen blended natural gas is gathered in the recirculation zone due to the vortex effect, which results in more serious accident consequences. With the increase in hydrogen blending ratio, the higher content of H and OH in the gas mixture significantly increases the premixed burning rate, the maximum overpressure rises rapidly when the hydrogen blend level increases beyond 40%. The results can provide a basis for construction safety design, risk assessment of leakage and explosion hazards, and emergency response in hydrogen blended natural gas distribution systems.     

Quantitative risk assessment using a Japanese hydrogen refueling station model

Although hydrogen refueling stations (HRSs) are becoming widespread across Japan and are essential for the operation of fuel cell vehicles, they present potential hazards. A large number of accidents such as explosions or fires have been reported, rendering it necessary to conduct a number of qualitative and quantitative risk assessments for HRSs. Current safety codes and technical standards related to Japanese HRSs have been established based on the results of a qualitative risk assessment and quantitative effectiveness validation of safety measures over ten years ago. In the last decade, there has been much development in the technologies of the components or facilities used in domestic HRSs and much operational experience as well as knowledge to use hydrogen in HRSs safely have been gained through years of commercial operation. The purpose of the present study is to conduct a quantitative risk assessment (QRA) of the latest HRS model representing Japanese HRSs with the most current information and to identify the most significant scenarios that pose the greatest risks to the physical surroundings in the HRS model. The results of the QRA show that the risk contours of 10^?3 and 10^?4 per year were confined within the HRS boundaries, whereas the risk contours of 10^?5 and 10^?6 per year are still present outside the HRS. Comparing the breakdown of the individual risks (IRs) at the risk ranking points, we conclude that the risk of jet fire demonstrates the highest contribution to the risks at all of the risk ranking points and outside the station. To reduce these risks and confine the risk contour of 10^?6 per year within the HRS boundaries, it is necessary to consider risk mitigation measures for jet fires.     

Rethinking “BLEVE explosion” after liquid hydrogen storage tank rupture in a fire

The underlying physical mechanisms leading to the generation of blast waves after liquid hydrogen (LH2) storage tank rupture in a fire are not yet fully understood. This makes it difficult to develop predictive models and validate them against a very limited number of experiments. This study aims at the development of a CFD model able to predict maximum pressure in the blast wave after the LH2 storage tank rupture in a fire. The performed critical review of previous works and the thorough numerical analysis of BMW experiments (LH2 storage pressure in the range 2.0–11.3 bar abs) allowed us to conclude that the maximum pressure in the blast wave is generated by gaseous phase starting shock enhanced by combustion reaction of hydrogen at the contact surface with heated by the shock air. The boiling liquid expanding vapour explosion (BLEVE) pressure peak follows the gaseous phase blast and is smaller in amplitude. The CFD model validated recently against high-pressure hydrogen storage tank rupture in fire experiments is essentially updated in this study to account for cryogenic conditions of LH2 storage. The simulation results provided insight into the blast wave and combustion dynamics, demonstrating that combustion at the contact surface contributes significantly to the generated blast wave, increasing the overpressure at 3 m from the tank up to 5 times. The developed CFD model can be used as a contemporary tool for hydrogen safety engineering, e.g. for assessment of hazard distances from LH2 storage.     

Development of uniform harm criteria for use in quantitative risk analysis of the hydrogen infrastructure

This paper discusses the preliminary results of the Risk Management subtask efforts within the International Energy Agency (IEA) Hydrogen Implementing Agreement (HIA) Task 19 on Hydrogen Safety to develop uniform harm criteria for use in the Quantitative Risk Assessments (QRAs) of hydrogen facilities. The IEA HIA Task 19 efforts are focused on developing guidelines and criteria for performing QRAs of hydrogen facilities. The performance of QRAs requires that the level of harm that is represented in the risk evaluation be established using deterministic models. The level of harm is a function of the type and level of hazard. The principle hazard associated with hydrogen facilities is uncontrolled accumulation of hydrogen in (semi) confined spaces and consecutive ignition. Another significant hazard is combustion of accidentally released hydrogen gas or liquid, which may or may not happen instantaneously. The primary consequences from fire hazards consist of personnel injuries or fatalities, or facility and equipment damage due to high air temperatures, radiant heat fluxes, or direct contact with hydrogen flames. The possible consequences of explosions on humans and structures or equipment include blast wave overpressure effects, impact from fragments generated by the explosion, the collapse of buildings, and the heat effects from subsequent fire balls. A harm criterion is used to translate the consequences of an accident, evaluated from deterministic models, to a probability of harm to people, structures, or components. Different methods can be used to establish harm criteria including the use of threshold consequence levels and continuous functions that relate the level of a hazard to a probability of damage. This paper presents a survey of harm criteria that can be utilized in QRAs and makes recommendations on the criteria that should be utilized for hydrogen-related hazards.     

Numerical study of hydrogen dispersion in a fuel cell vehicle under the effect of ambient wind

In the rescue of hydrogen-fueled vehicle accidents, once accidental leakage occurs and hydrogen enters the cabin, the relatively closed environment of the vehicle is prone to hydrogen accumulation. Excessive hydrogen concentration inside the vehicle cabin may cause suffocation death of injured passengers and rescue crews, or explosion risk. Based on hydrogen fuel cell vehicle (HFCV) with hydrogen storage pressure 70 MPa, four different scenarios (i. with opened sunroof, ii. opened door windows, iii. opened sunroof and door windows and iv. opened sunroof, door windows and rear windshield) under the condition of accidental leakage were simulated using computational fluid dynamics (CFD) tools. The hydrogen concentration inside the vehicle and the distribution of flammable area (>4% hydrogen mole fraction) were analyzed, considering the effect of ambient wind. The results show that in the case of convection between interior and exterior of the vehicle via the sunroof, door windows or rear windshield, the distribution of hydrogen inside the vehicle is strongly affected by the ambient wind speed. In the least risk case, ambient wind can reduce the hydrogen mole fraction in the front of the vehicle to less than 4%, however the rear of the vehicle is always within flammable risk.     

Exact algorithms for incremental deployment of hydrogen refuelling stations

Given the large investments required to establish hydrogen refuelling stations (HRSs) and the difficulty in forecasting the sales of fuel cell electric vehicles, incremental HRS deployment offers an efficient method of establishing hydrogen infrastructure with a sufficient load factor and low financial risk. Considering that some HRSs are already in use, this study assumed that the optimal location of a new HRS maximises its distance from existing HRSs and minimises its distance from customer demand points. Accordingly, a multi-objective location model and efficient exact solution methods were proposed to determine the optimal location of one or two new HRSs. As a case study, the solution methods were applied to supply hydrogen to an increasing captive fleet of taxis in a large metropolis such as Paris with fixed demand points. The methods can be widely applied to effectively install one or two HRSs incrementally.     

The impact of hydrogen refueling station subsidy strategy on China's hydrogen fuel cell vehicle market diffusion

Lack of hydrogen refueling stations (HRSs) has hindered the diffusion of hydrogen fuel cell vehicles (HFCVs) in the Chinese transport market. By combining the agent-based model (ABM) and the experience weighted attraction (EWA) learning algorithm, this paper explores the impact of government subsidy strategy for HRSs on the market diffusion of HFCVs. The actions of the parties (government, HRS planning department and consumers) and their interactions are taken into account. The new model suggests dynamic subsidy mode based on EWA algorithm yields better results than static subsidy mode: HFCV purchases, HRS construction effort, total number of HRSs and expected HRS planning department profits all outperform static data by around 27%. In addition, choosing an appropriate initial subsidy strategy can increase the sales of HFCVs by nearly 40%. Early investment from government to establish initial HRSs can also increase market diffusion efficiency by more than 76.7%.     

Safety analysis of leakage in a nuclear hydrogen production system

Due to its unique advantages, such as clean and pollution-free, hydrogen energy has gradually improved its energy transition position. Constructing nuclear hydrogen production systems is a necessary means to achieve large-scale hydrogen production, and the study of hydrogen leakage and diffusion behavior is critical to commercializing hydrogen production systems. In engineering practice, the distance between the hydrogen storage device and the nuclear power plant is an important indicator to measure the safety of nuclear hydrogen production. To study the influence of gas storage tank's own conditions and external environmental conditions on leakage diffusion, influencing factors such as wind speed, leakage direction, leakage diameter, leakage height, and leakage angle are discussed in the present study. By calculating severe working conditions combined with the above multiple factors, the longest distance of hydrogen diffusion is determined. Finally, peak overpressure impact generated by hydrogen explosion was evaluated, and the minimum separation distance required to avoid safety risks was predicted. The results demonstrate that when the wind direction is consistent with the leakage direction, and the leakage angle is 0°, the higher the wind speed, the larger the leakage diameter and the lower the leakage height, resulting in a longer diffusion distance. Under more extreme and severe working conditions, the diffusion distance of combustible hydrogen cloud can reach as far as 237 m. Once hydrogen diffusion explodes, the minimum separation distance required is about 338 m. This research provides an effective method for safety risk assessment of a nuclear hydrogen production system.     

Two-tier pressure consolidation operation method for hydrogen refueling station cost reduction

An operation strategy known as two-tier “pressure consolidation” of delivered tube-trailers (or equivalent supply storage) has been developed to maximize the throughput at gaseous hydrogen refueling stations (HRSs) for fuel cell electric vehicles (FCEVs). The high capital costs of HRSs and the consequent high investment risk are deterring growth of the infrastructure needed to promote the deployment of FCEVs. Stations supplied by gaseous hydrogen will be necessary for FCEV deployment in both the near and long term. The two-tier pressure consolidation method enhances gaseous HRSs in the following ways: (1) reduces the capital cost compared with conventional stations, as well as those operating according to the original pressure consolidation approach described by Elgowainy et al. (2014) [1], (2) minimizes pressure cycling of HRS supply storage relative to the original pressure consolidation approach; and (3) increases use of the station's supply storage (or delivered tube-trailers) while maintaining higher state-of-charge vehicle fills.     

Convenient storage of concentrated hydrogen peroxide as a CaO2·2H2O2(s)/H2O2(aq) slurry for energy storage applications

Prior investigations have proposed, and successfully implemented, a stand-alone supply of aqueous hydrogen peroxide for use in fuel cells. An apparent obstacle for considering the use of aqueous hydrogen peroxide as an energy storage compound is the corrosive nature of the nominally required 50 wt.% maximum concentration. Here we propose storage of concentrated hydrogen peroxide in a high weight percent solid slurry, namely the equilibrium system of CaO₂·2H₂O₂(s)/H₂O₂(aq), that mitigates much of the risk associated with the storage of such high concentrations. We have prepared and studied surrogate slurries of calcium hydroxide/water that are assumed to resemble the peroxo compound slurries. These slurries have the consistency of a paste rather than a distinct two-phase (liquid plus solid) system. This paste-like property of the prepared surrogates enable them to be contained within a 200 lines-per-inch. (LPI) nickel mesh screen (33.6% open area) with no solids leakage, and only liquid transport driven by an adsorbent material is placed in physical contact on the exterior of the screen. This hydrogen peroxide slurry approach suggests a convenient and safe mechanism of storing hydrogen peroxide for use in, say, vehicle applications. This is because fuel cell design requires only aqueous hydrogen peroxide use, that can be achieved using the separation approach utilizing the screen material here. This proposed method of storage should mitigate hazards associated with unintentional spills and leakage issues arising from aqueous solution use.