Safety

The MultHyFuel project notably aims to produce the data missing for usable risk analysis and mitigation activity for Hydrogen Refuelling Stations (HRS) in a multi-fuel context. In this framework realistic releases of hydrogen that could occur in representative multi-fuel forecourts were studied. These releases can occur inside or outside fuel dispensers and they can interact with a complex environment notably made of parked cars and trucks. This paper is focused on the most critical scenarios that were addressed by a sub-group through the use of Computational Fluid Dynamics (CFD) modelling. Once the corresponding source terms for hydrogen releases were known two stages are followed:<br/>♦ Model Validation – to evaluate the CFD models selected by the task partners and to evaluate their performance through comparison to experimental data.<br/>♦ Realistic Release Modelling – to perform demonstration simulations of a range of critical scenarios.<br/>The CFD models selected for the Model Validation have been tested against measured data for a set of experiments involving hydrogen releases. Each experiment accounts for physical features that are encountered in the realistic cases. The selected experiments include an under-expanded hydrogen jet discharging into the open atmosphere with no obstacles or through an array of obstacles. Additionally a very different set-up was studied with buoyancy-driven releases inside a naturally ventilated enclosure. The results of the Model Validation exercise show that the models produce acceptable solutions when compared to measured data and give confidence in the ability of the models and the modellers to capture the behaviour of the realistic releases adequately. The Realistic Release Modelling phase will provide estimation of the flammable gas cloud volume for a set of critical scenarios and will be described at the second stage.

A field test series where a composite pressure vessel for hydrogen is exploded by fire 1) to provide the facts and the data for the safety distance based on overpressure; 2) to validate the current status of mitigation barrier per KGS FP216 and further designs for developments of the codes and standards relating to hydrogen refueling stations. A pair of barriers to be tested are installed approximately 4 m apart standing face to face. The explosion source is a type-4 composite vessel of 175 L filled with compressed hydrogen up to 70 MPa. The vessel is in the middle of the barriers and the body part is heated with an LPG burner until it blows out. The incident overpressures from the blast are measured with 40 high-speed pressure sensors which are respectively installed 2 to 32 m away from the explosion. In the tests with the barrier constructed per the current status of KGS FP216 the explosion of the vessel resulted in partial destruction of the reinforced concrete barrier and made the steel plate barrier dissociated from the foundation then flew away approximately 25 m. The peak overpressure was 14.65 kPa at 32 m. The test data will be further analyzed to select the barriers for the subsequent tests and to develop the codes and standards for hydrogen refueling stations.

This work is part of the MULTHYFUEL E.U. research program [1] aiming at enabling the implementation of hydrogen dispersers in refuelling stations. One important challenge is the severity of accidents due to a leakage of hydrogen from a dispenser in the forecourt. The work presented in this paper deals with the quantification of the leakage scenarios in terms of frequencies and severities. The risk analysis exercise although performed by experts showed very large discrepancies between the frequencies of leakages of the same categories and even between the consequences. A large part of the disagreement comes from the failure databases chosen as shown in the paper. The mismatch between the components on which the databases have been settled and the actual hydrogen components may be responsible for this situation. However as it stands limited confidence can be laid on the outcome of the risk analysis.<br/>A new method is being developed to calculate the frequencies of the leakage and the flowrate based on an accurate description of each component and of each hazardous situation. For instance the possibility for a fitting to become untight due to pressure cycling is modelled based on the contact mechanics. Human errors can also be introduced by describing the tasks. In addition of the description of the method the application to a disperser is proposed with some comparison to experiments. One of the outcomes is that leakage cross sections can be much larger than expected.

Hydrogen is promoted as an alternative energy given the global energy shortage and environmental pollution. A scientific basiscan be provided for the safe use and emergency treatment of hydrogen based on hydrogen leakage and combustion behavior.This study examined the stagnation parameters of dynamic hydrogen leakage and flame propagation in turbulent jets undernormal temperatures and high pressure. Based on van der Waals’ equation of state for gas a theoretical model for completelypredicting stagnation parameters outlet gas velocity and flow rate changes in the process of high-pressure hydrogen leakagecould be proposed and the calculation result of this model was compared with the experimental result with an error within±10%. The progression and propagation of the flame in turbulent jets after ignition were recorded using the background-oriented schlieren image technology and the propagation speed of flame from the ignition position downward and upwardwas calculated. Moreover the influence of initial pressure nozzle diameter and ignition position on the flame propagationprocess and propagation speed was analyzed.

Quantitative Risk Assessments (QRA) is an important tool for enabling safe deployment of hydrogen technologies and is increasingly embedded in the permitting process. Following the framework developed in our companion paper we conducted a detailed QRA on the uncontrolled releases from a high-capacity hydrogen fueling station with liquid hydrogen (LH2) storage. We characterized gaseous and liquid hydrogen releases determined the causal pathways that led to them and the frequency of the potential hazardous outcomes. These hazardous scenarios were modeled to estimate their potential harm on station users. The analysis results reveal that the total frequency for a major hydrogen release is 1.48 × 10− 2 times per station-year. However considering the control barriers in the station the expected frequency of ignition events is reduced to 1.35 × 10− 5 ignition per stationyear. The expected fatality risk is within the tolerable limit for hydrogen fueling stations but still remains higher than that of conventional gasoline stations. The most severe scenario identified involves a high-pressure GH2 release leading to a jet fire with jet flames reaching up to 15 m in length. The most probable sources of GH2 releases are from the gaseous hydrogen filters while for LH2 releases cryogenic pumps are the primary contributors. To improve the accuracy of QRAs for LH2 systems we identified critical gaps including the need for improved reliability data that must be addressed.

The development of hydrogen production technologies and new uses represents an opportunity to accelerate the ecological transition and create a new industrial sector. However the risks associated with the use of hydrogen must be considered. Mitigation of a hydrogen explosion in an enclosure is partly based on prevention strategies such as detection and ventilation and protection strategies such as explosion venting. Even if applications involving hydrogen probably are most interesting for vented explosions in weak structures the extreme reactivity of hydrogen-air mixtures often excludes the use of regular venting devices such as in highly constrained urban environments. Thus having alternative mitigation solutions can make the effects of the explosion acceptable by reducing the flame speed and the overpressure loading or suppressing the secondary explosion. The objective of this paper is to present experimental studies of the mitigation of hydrogen-air deflagration in a 4 m3 vented enclosure by injection of inhibiting powder (NaHCO₃). After describing the experimental set-up the main experimental results are presented for several trial configurations showing the influence of inhibiting powder in the flammable cloud on flame propagation. An interpretation of the mitigating effect of inhibiting powder on the explosion effects is proposed based on the work of Proust et al.

A wireless near-field hydrogen gas sensor is proposed which detects the leaking hydrogen near its source to achieve fast response and high reliability. The proposed sensor can detect leaking hydrogen in 100ms with nearly no delay due to hydrogen diffusion in space. The overall response time is shortened by orders of magnitude compared to conventional sensors according to simulation results. Over 1 year of maintenance interval is empowered by wireless design based on Bluetooth low energy protocol.

In confined spaces hydrogen released with low momentum tends to accumulate in a layer below the ceiling; the concentration in this layer rises and can rapidly enter the flammability range. In this context ventilation is a key safety equipment to prevent the formation of such flammable volumes. To ensure its well-sizing to each specific industrial context it is necessary to dispose of reliable engineering models. Currently the existing engineering models dealing with the buoyancy-driven H2 dispersion in a ventilated enclosure mainly focus on the natural-ventilation phenomenon. However forced ventilation is in some situations more adapted to the industrial context as the wind direction and intensity remains constant and under control. Therefore two existing wind-assisted ventilation models elaborated by Hunt and Linden [1] and Lowesmith et al. [2] were tested on forced ventilation applications. The main assumption consists in assuming a blowing ventilation system rather than a suction system as the composition and velocity of the entering air are known. The fresh air enters the down opening and airhydrogen mixture escapes through the upper one. The adapted models are then validated with experimental data releasing helium rather than hydrogen. Experiments are conducted on a 1-m3 ventilated box controlling the release and ventilation rates. The agreement between both analytical and experimental results is discussed from the different comparisons performed.

Following a desktop study undertaken in 2021 to identify hazard scenarios associated with the use of liquid and compressed hydrogen on commercial shipping Shell has started a programme of large-scale experiments on the consequences of a release of liquid hydrogen. This work will compliment on-going research Shell has sponsored within several joint industry projects but will also address immediate concerns that the maritime industry has for the transportation of liquid hydrogen (LH2). This paper will describe the first phase of experiments involving the release of LH2 onto various substrates as well as dispersion across an instrumented test pad. These results will be used to address the following uncertainties in risk assessments within the hydrogen economy such as (1) Quantify the impact of low wind speed and high humidity on the buoyancy of both a passive and momentum jet dispersion cloud (2) Gather additional data on liquid hydrogen jet fires (3) Understand the likelihood for the formation of a sustained pool of hydrogen (4) Characterise materials especially passive fire protective coatings that are exposed to LH2. Not only will these experiments generate validation data to provide confidence in the Shell consequence tool FRED but they will also be used by Shell to support updates and new regulations developed by the International Maritime Organisation as it seeks to reduce CO2 intensity in the maritime industry.

Hydrogen is one of a handful of new low carbon solutions that will be critical for the transition to net zero. The upscaling of production and applications entails that hydrogen is likely to be stored in liquid phase (LH2) at cryogenic conditions to increase its energy density. Widespread LH2 use as an alternative fuel will require significant infrastructure upgrades to accommodate increased bulk transport storage and delivery. However current LH2 bulk storage separation distances are based on subjective expert recommendations rather than experimental observations or physical models. Experimental studies of large-scale LH2 release are challenging and costly. The existing large-scale tests are scarce and numerical studies are a viable option to investigate the existing knowledge gaps. Controlled or accidental releases of LH2 for hydrogen refueling infrastructure would result in high momentum two-phase jets or formation of liquid pools depending on release conditions. Both release scenarios lead to a flammable/explosive cloud posing a safety issue to the public.<br/>The manuscript reports exploratory study to numerically determine the safety zone resulting from cryogenic hydrogen releases related to LH2 storage and refueling using the in-house HyFOAM solver further modified for gaseous hydrogen releases at cryogenic conditions and the subsequent atmospheric dispersion and ignition within the platform of OpenFOAM V8.0. The current version of the solver neglects the flashing process by assuming that the temperature of the stored LH2 is equal to the boiling point at the atmospheric condition. Numerical simulations of dispersion and subsequent ignition of LH2 release scenarios with respect to different release orientations release rates release temperatures and weather conditions were performed. Both hydrogen concentration and temperature fields were predicted and the boundary of zones within the flammability limit was also defined. The study also considered the sensitivities of the consequences to the release orientation wind speed ambient temperature and release content etc. The effect of different barrier walls on the deflagration were also evaluated by changing the height and location.