Modelling of refuelling through the entire equipment of HRS: use of dynamic mesh to simulate heat and mass transfer during throttling at PCV

Hydrogen refuelling is imperative for the emerging market of hydrogen vehicles. The pressure control valve (PCV) at the hydrogen refuelling station (HRS) plays a major role in ensuring that hydrogen delivery to the vehicle follows the prescribed refuelling protocols. A three-dimensional CFD model with a detailed resolution of PCV motion affecting heat and mass transfer is developed. The PCV motion controlling the mass flow rate is simulated using dynamic mesh. The CFD model captures refuelling from high-pressure tanks through entire HRS equipment to onboard tanks, capturing pressure and temperature changes upstream and downstream of the PCV. The Joule-Thomson effect resulting in a hydrogen temperature increase at PCV is captured using the NIST real gas database. The model is validated against Test No.1 of NREL on refuelling through the entire equipment of HRS. The CFD model can be used to design HRS equipment parameters, including PCV, and develop efficient refuelling protocols.