TRUST – Safe Hydrogen Trailers for Small and Medium-Sized Businesses

The IGF project TRUST focuses on developing safe refueling procedures for hydrogen trailers. The project focuses on Type IV tanks due to their market dominance and specific safety requirements.

While standardised refueling protocols have already been implemented for hydrogen trucks and passenger cars, no comparable procedures exist for refueling trailers and MEGCs (Multiple-Element Gas Containers). The refueling of such systems is determined by the operator on a case-by-case basis under very conservative operating parameters. The goal of the TRUST (Trailer Refueling Utilizing Simulated Tables) project is to develop practical recommendations, simplified surrogate models, and user-friendly procedures for refueling these systems.

Problem Description

Local temperature peaks (e.g., hotspots) and temperature stratification that develop within the storage facility during the filling process pose problems. Their size, location, and deviation from the average gas temperature in the storage facility depend on both geometric and filling parameters. Exceeding the maximum permitted gas temperatures (usually +85°C) can lead to thermal overload of the liner material. In practice, however, these local temperature phenomena are not detectable and can therefore pose a safety risk.

Simulations as the Basis for Safe Filling Processes

The project aims to use experiments and CFD simulations to investigate the effects of various parameters in greater detail. The hydrogen test facility at the ZBT – The Hydrogen and Fuel Cell Center, provides the necessary platform for conducting the measurements required to validate the simulations. The simulations are carried out at the Chair of Fluid Dynamics (LFD) at the University of Duisburg-Essen, which specialises in large-eddy simulations (LES). LES provides precise predictions of temperature fields, hotspots, and potential boundary layer separations. These simulations are highly computationally intensive and require high-performance computers, which are available to the department. Even on high-performance computers, these simulations take several weeks to complete.

Simplified Models for Practical Application

Results from the LES will be used to validate less computationally intensive calculations based on Reynolds-Averaged Navier-Stokes (RANS) equations, which make it possible to derive simplified 0D/1D models that enable rapid analysis of filling processes. To this end, the existing HRS model the ZBT was utilised, which was developed as a design tool for hydrogen filling stations.

Validation and Verification Tests

In the area of measurements, the ZBT has experience gained through a wide variety of R&D projects (e.g., EU-PRHYDE) that can be utilised in this project. For example, existing test storage tanks equipped with specialised measurement technology to record temperature fields inside the tanks will be used. The facility set up at the hydrogen test site allows for customised, experiment-specific parameterisation to simulate realistic refueling scenarios.

Project information

Project Acronym: TRUST

Project Title: Simulation-Based Development of Procedures for the Safe Filling of Hydrogen Trailers

Project Period: 1 April 2026 – 30 September 2028

Funding Program: IGF Projects

Grant ID: 01IF24633N

Project budget: €524,394.72

Project partners:

Grants

Contact

Hydrogen Infrastructure Project Management

Lukas Willmeroth

+49 203 7598-2190

l.willmeroth@zbt.de

Portrait eines Manns mit Bart und grauem Jacket vor Bäumen

Skills

The project builds on the ZBT’s extensive expertise in the areas of hydrogen testing infrastructure, measurement and testing technology, and modeling and simulation. This infrastructure and expertise are also available to industry partners through development services and contract research.

Measurement and Testing Services – Experimental investigations and validation of hydrogen systems.
Modeling and Simulation – CFD simulations and model development for hydrogen applications.
Development Services – Development and optimization of safe hydrogen technologies.

Media

Other current projects

3. August, 2026

grELjet

As part of the grELjet project, ZBT is collaborating with Fraunhofer ENAS to develop spatially resolved, optimised catalyst layers designed to reduce the iridium requirements of PEM electrolysers and increase their efficiency.

3. August, 2026

NH3-HRS

The NH3-HRS project is developing a compact system that converts ammonia directly into high-purity hydrogen at hydrogen refueling stations.

31. July, 2026

H2B – Is Hydrogen the Right Solution for Energy-Intensive SMEs?

New Interreg Project H2B Provides Entrepreneurs with Clarity on Hydrogen as an Energy Solution.

30. July, 2026

GALWANi – Nanowire Electrodes for Alkaline Water Electrolysis

The GALWANi project is developing customized nickel and nickel-iron nanowire electrodes for more powerful and efficient alkaline electrolysers.

20. July, 2026

TRUST – Safe Hydrogen Trailers for Small and Medium-Sized Businesses

The IGF project TRUST (Trailer Refueling Utilizing Simulated Tables) focuses on developing safe refueling procedures for hydrogen trailers.

17. July, 2026

LongCell – Fuel Cell Lifespan Prediction and Lifespan-Optimised Operation

How can fuel cell systems be operated more efficiently, with a longer service life, and more cost-effectively? The new LongCell research project is dedicated to addressing this question.

17. July, 2026

ReMatKat – Reduction of Critical Materials in PEM Electrolysers

PEM electrolysers require rare, expensive, and otherwise critical materials, including iridium for the catalysts and PFAS for the membranes. The ReMatKat project aims to reduce the use of such materials.

16. July, 2026

EISBaEr – Innovative Sensor Technology for More Robust Fuel Cell Systems

A new type of sensor system for stationary fuel cell systems is designed to monitor relevant parameters in real time and enable precise operational control.