Hydrogen Fuel Stations: Accelerating the Shift to Green Mobility

Hydrogen fuel stations, also known as hydrogen refueling stations or H2 stations, are facilities that store and dispense hydrogen gas for use in fuel cell vehicles. These stations play a crucial role in the adoption of hydrogen as a clean, sustainable alternative to fossil fuels for transportation. In this article, we'll explore the different types of hydrogen fuel stations, their key components, the refueling process, safety measures, and the future of hydrogen infrastructure.

‍

Basics of Hydrogen as a Fuel

Hydrogen is the most abundant element in the universe and has the potential to be a clean, renewable fuel source. When used in a fuel cell, hydrogen combines with oxygen to produce electricity, with only water and heat as byproducts. This makes it an attractive alternative to traditional gasoline or diesel fuels, which produce harmful greenhouse gas emissions.

‍

Types of Hydrogen Fuel Stations

There are two primary types of hydrogen fuel stations: gaseous hydrogen stations and liquid hydrogen stations.

‍

Gaseous Hydrogen Stations

Gaseous hydrogen stations store hydrogen gas under high pressure, typically at 350 to 700 bar (5,000 to 10,000 psi). These stations compress the hydrogen, which is then stored in high-pressure tanks before being dispensed to vehicles. Gaseous hydrogen stations are the most common type of hydrogen refueling station.

‍

Liquid Hydrogen Stations

Liquid hydrogen stations store hydrogen in its liquid state at extremely low temperatures (-253°C or -423°F). These stations require more complex equipment and insulation to maintain the hydrogen at such low temperatures, but they offer advantages in terms of storage capacity and refueling speed.

‍

Key Components of a Hydrogen Fuel Station

A hydrogen fuel station typically consists of three main components:

1. Compressors: Compressors are used to increase the pressure of hydrogen gas, allowing it to be stored efficiently in tanks and dispensed to vehicles.
2. Storage Tanks: Storage tanks hold hydrogen gas under pressure until it's dispensed to a vehicle. Tanks at hydrogen fuel stations can store hydrogen in either gaseous or liquid form.
3. Dispensers: Dispensers are the interface between the fuel station and the vehicle. They provide a safe and controlled means of transferring hydrogen from the storage tanks to the vehicle's fuel cell system.

‍

The Hydrogen Refueling Process

Refueling a hydrogen-powered vehicle is similar to refueling a gasoline-powered vehicle. The driver parks near the dispenser, connects the dispenser nozzle to the vehicle's fuel receptacle, and initiates the refueling process. The dispenser then transfers hydrogen from the station's storage tanks to the vehicle's fuel cell system. The entire process usually takes between 3 to 5 minutes, comparable to refueling with gasoline or diesel.

‍

Safety Measures at Hydrogen Fuel Stations

Hydrogen fuel stations employ several safety measures to ensure the safe handling and storage of hydrogen. These measures include:

1. Leak detection systems that monitor for any potential hydrogen leaks in storage tanks, dispensers, and piping.
2. Ventilation systems that prevent the build-up of hydrogen gas in the event of a leak.

3. Emergency shut-off systems that automatically isolate the source of a leak and stop the flow of hydrogen.
4. Fire suppression systems designed to quickly extinguish any potential fires.
5. Training for station operators to ensure proper handling and maintenance of hydrogen fueling equipment.

‍

Benefits of Hydrogen Fuel Stations

Hydrogen fuel stations offer several advantages over traditional gasoline and diesel stations, including:

1. Reduced greenhouse gas emissions: Hydrogen fuel cell vehicles emit only water vapor and heat, significantly reducing transportation-related emissions.
2. Renewable fuel source: Hydrogen can be produced from a variety of renewable sources, such as water electrolysis powered by solar or wind energy.
3. Energy security: Hydrogen can be produced domestically, reducing dependence on imported oil.
4. Fast refueling times: Hydrogen refueling is similar in speed to gasoline refueling, providing a more convenient experience compared to electric vehicle charging.

‍

Challenges in Expanding Hydrogen Fuel Station Infrastructure

Despite the benefits, there are several challenges to expanding hydrogen fuel station infrastructure:

1. High capital costs: The construction and operation of hydrogen fuel stations require significant investments in equipment and technology.
2. Limited number of hydrogen-powered vehicles: The current market for hydrogen fuel cell vehicles is relatively small, limiting demand for hydrogen refueling stations.
3. Competition from electric vehicles: The growth of battery electric vehicles and charging infrastructure may impact the adoption of hydrogen fuel cell vehicles.

‍

The Future of Hydrogen Fuel Stations

The future of hydrogen fuel stations will likely depend on continued advancements in fuel cell technology, reductions in hydrogen production and storage costs, and increased demand for hydrogen-powered vehicles. As governments and private companies continue to invest in hydrogen infrastructure, the number of hydrogen fuel stations is expected to grow, further supporting the adoption of hydrogen as a sustainable transportation fuel.

‍

Conclusion

Hydrogen fuel stations are a critical component in the shift towards clean, sustainable transportation. As the number of hydrogen-powered vehicles increases, the development of a robust hydrogen fueling infrastructure will be essential. By understanding the different types of hydrogen fuel stations, their key components, and the refueling process, we can better appreciate the potential for hydrogen as a viable alternative to traditional fossil fuels.

‍

Sources

‍

U.S. Department of Energy - Hydrogen Fueling Stations

International Energy Agency (IEA) - The Future of Hydrogen

‍

‍

See all hydrogen refueling stations on Lhyfe Heroes

‍

To fill the tanks of clean, zero-emission vehicles, such as cars, forklifts, tractors, buses, trucks, refuse collection trucks, boats, trains, etc., filling stations must be supplied with hydrogen that is processed, compressed and delivered to them from a production site.  

‍

Filling up with hydrogen, as simple and quick as filling up with petrol

Let’s start by highlighting what doesn’t change! Filling up a new Mirai car in a hydrogen station is just as straightforward as refuelling a conventional combustion engine car. Only the filling unit is really different – hydrogen comes in kilograms rather than litres, but everything else is similar. You still have your pump, nozzle, terminal keypad and information screen, and above all the charging time is no different – in less than five minutes the tank is full, and the Mirai can set off again for around 650 kilometres.

‍

Behind the scenes at a hydrogen station

Before being able to distribute fuel, a hydrogen station must first complete several processes:

• First, the hydrogen must be stored in cylinder racks, tanks or tube trailers,
• It needs to be compressed (to 500 bar for vehicles that run on 350-bar hydrogen and to 900 bar for vehicles that run on700-bar hydrogen, which depends on the vehicle type),
• Then it must be stored again in tanks known as buffers.
• Before being distributed, the hydrogen must be cooled using an exchanger and a cold unit (for 700-bar stations only).
• Only then can the hydrogen be used to fill a tank via the hose and nozzle of the dispenser.

Hydrogen station infrastructure is built above ground and is simple to install, repair and upgrade.

‍

Who installs hydrogen stations?

In addition to developers and operators of service stations – who are diversifying their offer and promoting clean mobility with hydrogen – local authorities, companies, manufacturers or operators of vehicle/bus fleets can also install their own hydrogen stations for refuelling their fleet. Some such private operators also open their stations to the public.  

In some areas, ecosystems have been set up to co-develop stations that meet the needs of all local users.  

‍

What do the current hydrogen stations offer?

A hydrogen station’s offering can be defined based on a few main criteria:

• Compression: 350 bar and/or 700 bar ( or 35 and/or 70 MPa). Some hydrogen stations only deliver 350 bar, some only 700 bar, and others deliver both.
• Storage capacity: This ranges from a few kilos – for supplying a small light vehicle fleet – to several tonnes of hydrogen a day for refuelling trucks, boats, planes, trains, etc.
• Flow rate: Fuelling time will vary depending on the station’s flow rate, the vehicle and the vehicle’s fuelling protocol.

One sign that the sector is already mature is that there is a standard for hydrogen stations – the SAE J2601 standard establishes the protocol and process limits for supplying hydrogen to light fuel cell electric vehicles.

‍

Where are the first hydrogen stations?  

See the collaborative map of stations‍

France – which plans in its Hydrogen Plan to install more than 100 hydrogen stations in 2023 – must accelerate its network to allow individuals and professionals to fuel their vehicles within a timeframe that matches the plans of vehicle manufacturers and fuel distributors.

‍

Hydrogen stations are popping up everywhere in Europe (see our map) and will continue to achieve the goal of having one every 150km. But how does a hydrogen station work exactly? Today, I have a discussion with Simon Keusching, global Key Account Manager for Dover Fueling Solutions® (DFS), focusing on hydrogen solutions. DFS has experience of more than 130 years in the fuel and convenience retail industry and officially launched the DFS Hydrogen dispenser in 2022.

‍

Claire: What is the specificity of constructing a hydrogen station?

To explain how innovative it is, I like to compare it with diesel stations. There are some safety rules associated with both, obviously, but the process is pretty simple.

For hydrogen it is highly different because there is a full hydrogen process plant within the station, aggregating a lot of engineering components.

‍

C: Could you detail that hydrogen process happening within the station?

There are five main components aggregated:

· The offloading panel: it takes hydrogen from the tube trailer to the compressor

· The compressor: when you start to onload, at the beginning, you have a lot pressure in the tube trailer (350bar). But as the tube trailer is emptying, the pressure decreases also. The compressor works then to put more pressure on the hydrogen. The compressor also raises the pressure up to 450 bar so that more hydrogen can be stored on the station and the filling can be done quicker. For Heavy Duty Truck, the tank needs to be filled with 350 bar and 700 bar for passenger cars.

· The buffer: we need to store some hydrogen at high pressure in the station to make sure it is available any time at the right pressure and to store more hydrogen

· The cooling system: when we load a vehicle with hydrogen, and the charging is fast, it is heating a lot and could be dangerous: so we need to cool the hydrogen before. It could be done without cooling, but it would be longer.

· The dispenser and the nozzle: this part is responsible to regulate the pressure, the temperature, the flow and the quantity “delivered” into the car.

It looks complex inside but for a user the experience is very similar: very fast!

‍

C: We see a lot of new energy solutions for vehicles, and it is sometime confusing to know which one to choose. What is your opinion on that?

Indeed, there are a lot of alternative fuels, at the moment. For example:

· Gas, CNG, LPG, LNG. These are still fossil fuels that burn in the engine. They reduce emissions by around 30%.

· Bio-gas. This is also a solution that we can liquify and use in the same infrastructure as LNG. Transforming waste into gas is also an interesting solution but it still emits CO2 when the vehicle runs.

For me, the main solutions for the future are:

· Green hydrogen: for heavy duty trucks, vehicles running a lot, etc.

· Decarbonized electricity: for light cars.

· E-fuels produced with green hydrogen for even more powerful solutions.

Hydrogen is still at the beginning, what are the next hurdles to come across?

The goal is to standardize the equipment and the mass production of every component. Almost every player of the hydrogen value chain has to scale up in the upcoming years. The demand is here but we need to have the right people, the right components and we need them quickly.

The positive points are that there is a lot of private and public investments done, AND now, it looks like everyone starts to align on a big ambition for hydrogen.

‍

You want to learn more about hydrogen at Dover Fueling solutions? Discover their podcast episodes:

• Hurrah for Hydrogen
• Discussing Decarbonization: Part 1
• Discussing Decarbonization: Part 2

‍