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

Rückseite einer Sattelzugmaschine von MAN und eines Toyota Mirai während des HeavyDuty Congress 2025

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

OptiCold – Safe cold start for fuel cells in mobile applications

OptiCold develops materials, cell architectures and operating strategies to enable PEM fuel cells to start safely and without damage even at temperatures as low as -25 °C. The aim is to provide robust, durable and practical solutions, especially for mobile heavy-duty applications.

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Excerpt from an XTM image showing water distribution in a fuel cell in a channel of a bipolar plate and the adjacent gas diffusion layer

FLOWMEX – More efficient fuel cells through systematically improved water management

Researchers want to significantly improve water management in fuel cells. Using model-based and experimental methods, they are developing a simulation tool that realistically depicts the transport of liquid water in gas diffusion layers and flow field channels.

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Interface – Microstructured Bipolar Plates for Greater Power Density and Service Life

Using innovative laser-based microstructuring, this research project optimises the interface between the bipolar plate and the gas diffusion layer in fuel cells. This improves water flow and reduces electrical contact resistance, resulting in a performance increase of up to 30% and a significantly longer service life.

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Test-Brennstoffzelle

Corromap – Real-time Corrosion Measurements for Optimising Fuel Cells

Corrosion limits the performance and service life of fuel cells, which are important for a hydrogen economy. Against this background, the Corromap research project focuses on corrosion measurements during cell operation. Project partners are the South Westphalia University of Applied Sciences in Iserlohn and the Hydrogen and Fuel Cell Center Duisburg (ZBT).

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HRS-Model – Free Simulation Model for Calculating 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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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.