Thermodynamic Modelling and Sensitivity Analysis of a 70 MPa Hydrogen Storage System for Heavy Duty Vehicles

Reducing CO2 emissions in transport requires sustainable alternatives such as fuel cell electric vehicles. A critical challenge is the efficient and safe storage and fast refueling of hydrogen at 70 MPa. This study proposes a practical design-support tool to optimize hydrogen storage systems for heavy-duty vehicles with capacities up to 100 kg. A customizable, dynamic Matlab-Simulink model was developed, including all components from dispenser to onboard tanks, enabling evaluation of multiple design options. The aim is to provide clear guidelines to ensure fast, safe, and complete refueling compliant with SAE J2601-5 limits. Simulations showed Type III tanks deliver the best performance. The fastest refueling (~10 min) was achieved with shorter pipes, larger diameters and low temperatures (20 °C ambient, −40 °C dispenser), while Average Pressure Ramp Rate was maximized up to 9 MPa/min (220 g/s of hydrogen from the dispenser) without exceeding SAE limits for pressure and temperature.