Optimizing hydrogen refueling station layout based on consequences of leakage and explosion accidents

The construction of hydrogen refueling stations (HRSs) is crucial in supporting the comprehensive popularization of hydrogen energy. However, many countries have difficulties expanding hydrogen infrastructure due to the high risk of hydrogen. In this work, a Computational Fluid Dynamics three-dimensional model is combined with individual lethality probability models to study the consequences of a leak explosion at the main components within a HRS. Two new canopies of hydrogen dispensers are designed to improve hydrogen evacuation efficiency. Results indicate that the safety distance based on the individual risk between the main equipment in the station can be reduced by 21.7%–67.0% compared with the actual layout distance. And the safety distance between dispensers, which is not specified in Chinese standards, is proposed to be 6.8 m. When the inclination angle of the dispenser canopy does not exceed 15° and the width does not exceed 12 m, the hydrogen leaking from the top of the dispenser has the smallest retention volume. Moreover, the tube trailers are advised to avoid parking in HRSs due to the increased consequences of explosive accidents.