The safe side of hydrogen

A digital twin approach

Absztrakt

We currently depend on two raw materials that are both finite and highly polluting to our health and atmosphere. The current global situation could be a good economic, cultural and mental prelude to the post-oil era. Much more stable and predictable energy security is needed. Due to global climate conditions, it is advisable to give priority to fuels with high energy content and relatively easy production, such as hydrogen. However, the widespread deployment of hydrogen refuelling stations is hampered by significant safety challenges, including hydrogen’s high flammability, its tendency to leak and its high-pressure storage requirements. This study investigates how digital twin technology can be used to improve the safety and operational efficiency of hydrogen facilities. A dynamic digital twin model was developed using the MATLAB/Simulink environment, replicating critical components such as the compressor, high-pressure buffer tank, heat exchanger, cooler and dispenser. The methodology involved integrating real-time data streams with virtual models and validating the simulation with operational data from an existing Hungarian refuelling station. The results show that the digital twin system accurately tracks critical parameters, with the vehicle tank temperature reaching 61.5 °C and the storage pressure rising to 955 bar, both within the safe operating range. The simulation confirmed that the system provides effective real-time leak detection, automatic alarms and accurate mass flow measurement, delivering 6.2 kg of hydrogen during a 300-second refuelling period. In conclusion, the digital twin technology offers significant potential for the safe development of hydrogen infrastructure by enabling predictive maintenance and optimized energy consumption. While challenges such as big data and infrastructure costs remain, the integration of artificial intelligence and advanced sensors into the digital twin will play a key role in the transition to a sustainable and reliable hydrogen economy.