Introduction  Hydrogen refueling station is the key infrastructure for the promotion of hydrogen fuel cell vehicles. 70 MPa hydrogen refueling can significantly improve the endurance and economy of hydrogen fuel cell vehicles. This paper aims to accurately analyze the energy consumption and reduce the operating cost of 70 MPa hydrogen refueling station.

  Method  The dynamic thermodynamic model of the hydrogen refueling process was established for the 70 MPa hydrogen refueling station. The law of dynamic pressure and temperature change during single hydrogen refueling process was studied based on the SAE J2601 refueling protocol. The energy consumption composition of single hydrogen refueling, and the energy consumption change of multiple times of hydrogen refueling were analyzed.

  Result  The results show that during single hydrogen refueling process, the onboard hydrogen storage cyclinder is refueled in 165 s, the high-pressure hydrogen storage cyclinder is refilled in 295 s, and one hydrogen refueling cycle is completed within 5 min. The energy consumption of hydrogen refueling comes from compressor, intercooler and precooler, among which the energy consumption of the compressor is more than 64%, and the energy consumption of the intercooler is about one third of that of the compressor. The specific energy consumption during single hydrogen refueling process increases from 0.98 kWh/kg to 1.24 kWh/kg as the number of times of hydrogen refueling increases from the first to the twentieth.

  Conclusion  The time of single hydrogen refueling process can be shortened by increasing the compressor flow rate. Reducing compressor energy consumption is the key to save energy in hydrogen refueling process. The pressure configuration of the three-stage high-pressure hydrogen storage cyclinder affects many parts of energy consumption. How to allocate the three-stage pressure is worth further study.