H2 REFUELING STATION TECHNOLOGY

A hydrogen test refuelling station is available at the ZBT as part of the hydrogen test field. It is used for the development, testing and optimisation of HRS components and refuelling protocols under real-world conditions. Modelling and simulations support this work to design HRS more efficiently and optimise existing facilities.

In national and international projects, the ZBT investigates heavy-duty refuelling systems and refuelling station components and develops refuelling strategies for 350, 500 and 700 bar. The test refuelling station enables tests on fully instrumented individual storage tanks, thereby contributing to the further development of the hydrogen infrastructure.

Hydrogen capacity:
– 500 kg H2 (stored at 200, 500 and 900 bar)
– a further 150 kg (at 1000 bar) planned

Pre-cooling:
– minus 40 °C to ambient temperature (solid-state and plate heat exchangers)
– minus 40 °C to +40 °C planned

Refuelling:
– 70 MPa Light Duty
– 35 MPa Heavy Duty
– 70 MPa Heavy Duty planned

Mass flow rates:
– up to 120 g/s
– up to 300 g/s planned

Refuelling protocols:
– SAE J2601 (2020)
– Table-based and MC form
– PRHYDE
– ‘freely’ configurable

– Max. size of the tank system: several m³
– Available FCEV tanks: fully instrumented 35, 50 & 70 MPa tanks
– PLC: Flexible and safety-critical control and data acquisition
– Test facility: Component development and testing

Efficient and safe hydrogen refuelling requires innovative tank systems, optimised refuelling protocols and reliable components. At ZBT, these technologies are developed, tested and further qualified to enable standard-compliant and practical refuelling.

Efficient and safe hydrogen refuelling requires innovative tank systems, optimised refuelling protocols and reliable components. At ZBT, these technologies are developed, tested and further qualified to enable standard-compliant and practical refuelling.

Tank systems, sensors and refuelling protocols must function reliably. The ZBT offers comprehensive testing to ensure the performance of H₂ refuelling stations.

From plant design to certification – the ZBT supports operators and manufacturers in implementing safe and efficient hydrogen refuelling stations.