ENHANCING HIGH-FLOW HYDROGEN REFUELING: MITIGATION OF PRESSURE LOSSES IN STORAGE AND DELIVERY SYSTEMS

High-flow hydrogen refuelling is essential for heavy-duty fuel cell electric vehicles but is hindered by significant pressure losses in storage and delivery systems. This study uses 1D simulations in GT-Suite with GEM-3D to analyse a hydrogen refuelling station modelled on an existing site in the Czech Republic. Initial designs showed high pressure drops, particularly in narrow or complex pipe sections. A redesigned bundle with larger diameters and simplified geometry reduced total pressure losses by over 50%, achieving sub-1 bar losses at 100–200 g/s. These findings support the development of efficient, high-flow hydrogen infrastructure in line with SAE J2601/5 standards.