Optimizing hydrogen storage during fast refueling using pre-cooling and renewable thermal management

• Pre-cooling hydrogen to −20 °C increases storage density by up to 166 %. • A solar-powered hydrogen refueling station model is developed for Morocco. • Effective thermal management ensures optimal efficiency at 700 bar refueling. • Economic analysis shows solar energy lowers the levelized cost of hydrogen. • Type 4 tanks outperform type 3 in high-frequency refueling applications. Hydrogen is increasingly recognized as a clean energy carrier for decarbonizing the transport sector. However, the high temperatures generated during high-pressure hydrogen filling reduce storage efficiency and safety. This study investigates pre-cooling strategies and renewable-powered thermal management as effective solutions to improve refueling performance and economic feasibility. Using H2Fills simulation software, hydrogen filling was modeled under varying inlet temperatures (−40 °C to 20 °C) and pressure ramp rates (11–21 MPa/min) for Type 3 and Type 4 tanks. Results show that pre-cooling hydrogen to −20 °C increases the state of charge from 19 % to 93 % and enhances storage mass by 166 % compared to refueling at 20 °C. Type 4 tanks, featuring composite liners, required 320 kJ of cooling energy versus 830 kJ for Type 3 at 21 MPa/min. A techno-economic assessment for Casablanca, Morocco, revealed that, for 500 vehicles/day, solar-powered pre-cooling systems required 17.8 kWp photovoltaic capacity and a capital cost of $112,910 for Type 4 tanks, compared to 13.2 kWp and $83,856 for Type 3. Although Type 4 systems demand higher investment, their improved thermal behavior and shorter refueling times make them more suitable for high-throughput hydrogen refueling stations.