Numerical investigation of a smart dual-feedback control strategy for hydrogen refueling: Towards energy-efficient type IV tanks filling

Université Moulay Ismail (UMI), Laboratoire d’Etude des Matériaux Avancés et Applications (LEM2A), Ecole Supérieure de Technologie de Meknès, Km 5, route d’Agouray, N6, 50040, Morocco.

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published online: 22 May 2026

Abstract

Rapid hydrogen refueling generates a significant amount of heat, which put at risk the strength of Type IV tanks. In practice, to counteract the heat produced, the SAE J2601 standard may require static precooling to -40°C in demanding conditions, which consumes a lot of energy. This study proposes a “dual feedback” control method that dynamically adjusts the mass flow and inlet temperature. Based on a 3D CFD model and Real Gas EOS, this method favors strict monitoring of the local HDPE coating temperature (<85°C) rather than the average gas temperature in order to prevent delamination, as required by recent safety requirements (e.g., BSI). Results obtained to date indicate that filling based on thermal limits, while improving the average injection temperature, reduces the consumption of the pre-cooling system compared to the standard method.