TY - JOUR
T1 - Analysis and design for ensuring release safety of Multi-Hydrogen cylinder bundles under real fire experiment
AU - Liu, Jie
AU - Li, Jianwei
AU - Mao, Zhanxin
AU - Bao, Huanhuan
AU - Ge, Xiaocheng
AU - Wan, Xinming
AU - He, Hongwen
AU - Sun, Fengchun
N1 - Publisher Copyright:
Copyright © 2026. Published by Elsevier Ltd.
PY - 2026/10/1
Y1 - 2026/10/1
N2 - During a fire incident, onboard hydrogen storage cylinders in fuel cell vehicles (FCVs) pose a risk of explosion or deflagration, and the risk may be greater for multi-hydrogen cylinder bundles (MHCB). To explore the safety issues associated with the simultaneous release of hydrogen from multiple cylinders, this study for the first time publicly reports a real fire experiment on an actual high-pressure hydrogen-filled MHCB of four hydrogen cylinders. The experiment obtains the hydrogen temperature and pressure changes inside each tank from the start of the fire until the complete release of hydrogen. During the releasing process, the hydrogen release pipeline (HRP) experiences serious plastic deformation due to the jet recoil force, so that hydrogen cannot be discharged in the prescribed direction, which brings significant safety hazards for real FCV applications. To address this issue, a stress simulation of the thermal pressure relief device (TPRD) hydrogen-releasing process is performed. By analyzing the forces at the fracture locations of the HRP, several potential optimization structures are proposed. The stress and strain conditions of these optimized HRPs are also discussed, which can provide guidance for the structural safety design of HRPs.
AB - During a fire incident, onboard hydrogen storage cylinders in fuel cell vehicles (FCVs) pose a risk of explosion or deflagration, and the risk may be greater for multi-hydrogen cylinder bundles (MHCB). To explore the safety issues associated with the simultaneous release of hydrogen from multiple cylinders, this study for the first time publicly reports a real fire experiment on an actual high-pressure hydrogen-filled MHCB of four hydrogen cylinders. The experiment obtains the hydrogen temperature and pressure changes inside each tank from the start of the fire until the complete release of hydrogen. During the releasing process, the hydrogen release pipeline (HRP) experiences serious plastic deformation due to the jet recoil force, so that hydrogen cannot be discharged in the prescribed direction, which brings significant safety hazards for real FCV applications. To address this issue, a stress simulation of the thermal pressure relief device (TPRD) hydrogen-releasing process is performed. By analyzing the forces at the fracture locations of the HRP, several potential optimization structures are proposed. The stress and strain conditions of these optimized HRPs are also discussed, which can provide guidance for the structural safety design of HRPs.
KW - Hydrogen safety
KW - Multi-hydrogen cylinder bundles
KW - Real fire experiment
KW - Release
UR - https://www.scopus.com/pages/publications/105032647671
U2 - 10.1016/j.fuel.2026.139033
DO - 10.1016/j.fuel.2026.139033
M3 - Article
AN - SCOPUS:105032647671
SN - 0016-2361
VL - 421
JO - Fuel
JF - Fuel
M1 - 139033
ER -