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Green hydrogen presents a promising solution for transitioning from fossil fuels to a clean energy future, particularly with the application of fuel cell electric vehicles (FCEVs). However, the hydrogen refuelling process for FCEVs requires extensive pre-cooling to achieve fast filling times. This study presents experiments and simulations of a hydrogen refuelling station equipped with an adaptable cold-fill unit, aiming to maximize fuelling efficiencies. For this purpose, we developed and experimentally validated simulation models for a hydrogen tank and an aluminium block heat exchanger. Different pre-cooling parameters affect the final tank temperatures during the parallel filling of three 350 L type IV tanks. The results indicate significant potential for optimizing the required cooling energy, with achievable savings of over 50 % depending on the pre-cooling strategy. The optimized pre-cooling strategies and energy savings aid in advancing the refuelling process for FCEVs, effectively contributing to the transition to clean energy. • Development and validation of an aluminium block heat exchanger model. • Development and validation of a 0D tank model. • Refuelling tests of a type IV tank dummy for heavy-duty applications. • Experimental investigation of different cooling strategies. • Parameter studies of the refuelling process with pre-cooling. [ABSTRACT FROM AUTHOR]

Hydrogen plays a vital role in decarbonizing the mobility sector. With the number of hydrogen vehicles expected to drastically increase, a network of refuelling stations needs to be built to keep up with the hydrogen demand. However, further research and development on hydrogen refuelling infrastructure, storage and standardization is required to overcome technical and economic barriers. Simulation tools can reduce time and costs during the design phase, but existing models do not fully support calculations of complete and arbitrary system layouts. Therefore, a flexible simulation toolbox for rapid investigations of hydrogen refuelling and extraction processes as well as development of refuelling infrastructure, vehicle tank systems and refuelling protocols for non-standardized applications was developed. Our model library, H2VPATT, comprises of typical components found in refuelling infrastructure. The key component is the hydrogen tank model. The simulation model was successfully validated with measurement data from refuelling tests of a 320 l type III tank. [Display omitted] • Development of a flexible and customizable tool for hydrogen filling/storage systems. • Model for simulation of custom refuelling protocols. • Model validation with experiments. [ABSTRACT FROM AUTHOR]