H2 refuelling station technology

For the market introduction of fuel cell-based mobility, efficient and cost-effective refuelling technologies for passenger cars, commercial vehicles, trucks, buses, trains, etc. must be developed. The ZBT’s Hydrogen Infrastructure department focuses on the targeted development and qualification of components and concepts for hydrogen refuelling stations (HRS). One focus is on refuelling protocols.

All activities at our hydrogen test filling station are based on a systemic approach, i.e. the effects on the overall system are always taken into account. Consequently, components and concepts are also developed and qualified in the related areas of distribution and tank systems. Our hydrogen test filling station is part of the hydrogen test field and enables realistic operation. As it is not a commercial filling station, we can develop and test components and concepts undisturbed under real conditions.

The R&D work is supported by modelling and simulation of filling systems, HRS, HRS components and refuelling. Based on these models, new HRS can be designed in a load-dependent, optimised manner and existing systems can be optimised in terms of their operation.

As part of numerous national and international R&D projects and customer orders, heavy-duty tank systems and filling station components have been investigated and the development of HD refuelling protocols has been supported by tests on fully instrumented individual storage tanks with 350, 500 and 700 bar.

What we offer – Development and qualification of …

  • Tanks/tank systems

  • Sensors

  • Pre-cooling

  • Compressors

  • Refuelling components and assemblies

  • Refuelling protocols

  • HRS concepts

Testing of …

  • Refuelling protocols and

  • Tank systems

Consulting on …

  • HRS and H2 plant planning

  • Process planning and control

  • Safety concepts

  • Approval and certification

Hauptdispenser der Wasserstoff-Testtankstelle am ZBT

Specifications of our test filling station

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

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

  • Refuelling:
    70 MPa light duty
    35 MPa heavy duty
    70 MPA heavy duty planned

  • Mass flows:
    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 tank system:
    Several m3

  • Available FCEV tanks:
    Fully instrumented 35, 50 & 70 MPa containers

  • PLC:
    Flexible and safety-related control and data acquisition

  • Test room:
    Component development and testing

Projects

Free simulation model for the calculation of hydrogen refuelling systems

Designing hydrogen refuelling systems for reliable and safe operation is a major challenge due to constantly changing requirements and rapid technological development. The HRS-Modell which has now been published, aims to help.

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“FaeBS”: Functional design and testing of an innovative fuel cell system

Within the framework of this industry-oriented cooperation project “FaeBS”, prototypes of a high-performance innovative fuel cell system (BZS) are to be developed and tested in a compact and space-optimised manner using innovative new components. The main focus of ZBT is the qualification of suitable materials for components.

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Project launch: DAC-2-E-Methane – storing green electricity surpluses in e-methane

Storing green electricity chemically instead of regulating it – this is possible with hydrogen and its derivatives. E-methane is a climate-neutral energy source if the carbon is captured from the air. A project that has now been launched is exploring the technical possibilities.

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Project launch: Development of a multi-port cathode valve for fuel cell systems

Multi-port valves could reduce the number of valves in the cathode path of fuel cell systems, with advantages for mobile applications in particular. ZBT and Rheinmetall-Pierburg want to develop such a valve in order to reduce the use of materials and resources as well as costs in fuel cell production. ZBT is focussing on simulation, material tests and functional and endurance tests.

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MUSCL: ZBT develops degradation model for optimising the operating strategy of fuel cell trucks

Fuel cell systems can be a sustainable alternative to diesel drives in long-distance lorry transport. In a new research project, ZBT is developing a degradation model to simultaneously maximise the energy efficiency and service life of fuel cells through efficient operating strategies.

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Contact

Group Lead H2 Refuelling Station Technology

Dr.-Ing. Christian Spitta
+49 203 7598-4277

Projects

The ZBT conducts research, development and consulting in the fields of hydrogen, fuel cells and electrolysis. In its research projects, the ZBT covers the entire spectrum from basic research, primarily in the field of new materials, to application-oriented research and R&D projects for industry.

Equipment

We have high-end laboratories, a wide range of measuring instruments and individually developed test benches. In the Hy-Lab, we analyse hydrogen samples for purity and contamination. On our hydrogen test field, we examine the interaction of systems and components on a 1:1 scale. And at the hydrogen test station, we develop hydrogen filling stations and refuelling protocols.