PhD Scientific Days 2026

Health Sciences 1.

Increasing the Safety of Hydrogen Filling Stations Using CFD Simulation and Digital Twin Technology

Name of the presenter

Hasulyo, Gabor

Institute/workplace of the presenter

Institute of Mining and Energy/ University of Miskolc

Authors

Gabor Hasulyo¹
1: University of Miskolc

Text of the abstract

One of the fundamental cornerstones for the global expansion and social acceptance of hydrogen-based transportation is the guaranteed safe operation of hydrogen refueling stations (HRS). Due to hydrogen’s unique properties—such as its wide flammability range (4–77% v/v) and high-pressure storage requirements (up to 950 bar)—traditional safety methods often reach their limits in ensuring public health and occupational safety. This study, supported by the Institute of Mining and Energy at the University of Miskolc, investigates how Computational Fluid Dynamics (CFD) and Digital Twin (DT) technology can revolutionize risk management to prevent catastrophic human injury and environmental exposure. Using PHAST Standalone 9.1, we simulated hydrogen diffusion at a release rate of 1 kg/s by simulating different wind speeds (1 m/s, 2 m/s and 5 m/s). At low wind speeds, the buoyancy of hydrogen causes vertical dispersion. The results identify critical propagation behaviors, at higher wind speeds (5 m/s) the gas cloud forms a horizontal profile at ground level, which increases the direct exposure and risk of explosion trauma to personnel and bystanders. Our models quantify that a potential explosion could generate 6 bar of overpressure—a value far exceeding the threshold for fatal primary blast injuries, such as pulmonary hemorrhage and eardrum rupture—underscoring the vital need for precision-engineered safety barriers. Complementing this, a Digital Twin integrated with AI-based decision-making was developed to act as a proactive health-monitoring system. During a simulated 300-second refueling process where 6.2 kg of hydrogen was transferred at 20 g/s, the twin verified that heat exchangers kept the system at a safe 60°C, preventing thermal-induced material fatigue and subsequent accidental injuries. This holistic approach transitions from reactive measures to preventive health protection, optimizing the placement of safety equipment to safeguard human life. By reducing the probability of industrial accidents and ensuring physiological integrity, these digital tools are essential for fostering the public trust necessary for a sustainable, health-conscious green energy transition and a successful hydrogen economy.

My e-mail address: gabor.hasulyo@uni-miskolc.hu