Optimization of the overall energy consumption in cascade fueling stations for hydrogen vehicles

Hydrogen fueling stations are emerging around and in larger cities in Europe and United States together with a number of hydrogen vehicles. The most stations comply with the refueling protocol made by society of automotive engineers and they use a cascade fueling system on-site for filling the vehicles. The cascade system at the station has to be refueled as the tank sizes are limited by the high pressures. The process of filling a vehicle and afterward bringing the tanks in refueling station back to same pressures, are called a complete refueling cycle. This study analyzes power consumption of refueling stations as a function of number of tanks, volume of the tanks and the pressure in the tanks. This is done for a complete refueling cycle. It is found that the energy consumption decreases with the number of tanks approaching an exponential function. The compressor accounts for app. 50% of the energy consumption. Going from one tank to three tanks gives an energy saving of app. 30%. Adding more than four tanks the energy saving per extra added tank is less than 4%. The optimal numbers of tanks in the cascade system are three or four.