Multi-Seasonal Risk Assessment of Hydrogen Leakage, Diffusion, and Explosion in Hydrogen Refueling Station

Yaling Liu, Yao Zeng, Guanxi Zhao, Huarong Hou (), Yangfan Song and Bin Ding
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Yaling Liu: Sichuan Special Equipment Inspection and Research Institute, Chengdu 610100, China
Yao Zeng: Sichuan Special Equipment Inspection and Research Institute, Chengdu 610100, China
Guanxi Zhao: Sichuan Special Equipment Inspection and Research Institute, Chengdu 610100, China
Huarong Hou: Hebei Key Laboratory of Low Carbon and High Efficiency Power Generation Technology, North China Electric Power University, Baoding 071003, China
Yangfan Song: Hebei Key Laboratory of Low Carbon and High Efficiency Power Generation Technology, North China Electric Power University, Baoding 071003, China
Bin Ding: College of New Energy, China University of Petroleum (East China), Qingdao 266580, China

Energies, 2025, vol. 18, issue 15, 1-23

Abstract: To reveal the influence mechanisms of seasonal climatic factors (wind speed, wind direction, temperature) and leakage direction on hydrogen dispersion and explosion behavior from single-source leaks at typical risk locations (hydrogen storage tanks, compressors, dispensers) in hydrogen refueling stations (HRSs), this work established a full-scale 1:1 three-dimensional numerical model using the FLACS v22.2 software based on the actual layout of an HRS in Xichang, Sichuan Province. Through systematic simulations of 72 leakage scenarios (3 equipment types × 4 seasons × 6 leakage directions), the coupled effects of climatic conditions, equipment layout, and leakage direction on hydrogen dispersion patterns and explosion risks were quantitatively analyzed. The key findings indicate the following: (1) Downward leaks (−Z direction) from storage tanks tend to form large-area ground-hugging hydrogen clouds, representing the highest explosion risk (overpressure peak: 0.25 barg; flame temperature: >2500 K). Leakage from compressors (±X/−Z directions) readily affects adjacent equipment. Dispenser leaks pose relatively lower risks, but specific directions (−Y direction) coupled with wind fields may drive significant hydrogen dispersion toward station buildings. (2) Southeast/south winds during spring/summer promote outward migration of hydrogen clouds, reducing overall station risk but causing localized accumulation near storage tanks. Conversely, north/northwest winds in autumn/winter intensify hydrogen concentrations in compressor and station building areas. (3) An empirical formula integrating climatic parameters, leakage conditions, and spatial coordinates was proposed to predict hydrogen concentration (error < 20%). This model provides theoretical and data support for optimizing sensor placement, dynamically adjusting ventilation strategies, and enhancing safety design in HRSs.

Keywords: hydrogen refueling station (HRS); hydrogen safety; FLACS; hydrogen leakage; risk assessment; gas cloud explosion; full-scale 3D model; coupling effects; climatic conditions (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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