Digital Twin Technology for Safety Enhancement of Hydrogen Refuelling Stations

Abstract:

Motor vehicles are part of our everyday life, and it is difficult to conceive mobility without them as they represent a form of independence. However, conventional vehicles are being transformed not only from a technological perspective, but also from their propulsion systems. This transformation is driven by the scarcity of fossil fuel reserves, geopolitical concerns, environmental pollution, energy transition challenges, and energy independence goals. The electro-mobility of the future will extend beyond electric vehicles to become an integral part of a diverse green energy mix. Hydrogen, with its zero emissions and high energy content, has gained significant attention in this context. The adoption of such new technology by society requires ensuring safety to prevent accidents that could hinder its evolution. High-priority research directions in the hydrogen economy include safety as a technical, psychological, and sociological issue. The safe and effective operation of hydrogen refuelling stations presents numerous challenges due to hydrogen's physical properties, such as its propensity to leak, flammability, and high-pressure storage requirements. Digital twin technology, which creates virtual replicas of physical systems based on real-time data, has significant potential to address these challenges. This study examines how digital twin technology can be implemented to operate hydrogen facilities more safely and effectively. Hydrogen, as a clean energy carrier, plays a key role in sustainable energy systems, but its handling poses substantial safety challenges. This research provides insights into the potential, benefits, and future outlook for digital twin technology in hydrogen refuelling stations, particularly for enhancing safety and reliability. The findings demonstrate that digital twin technology offers considerable potential for safely developing hydrogen infrastructure and may play a crucial role in transitioning to a sustainable energy system. The study describes the four main components of the technology: physical entity, virtual model, data flow, and analytical system, collectively demonstrating practical applications where 3D visualization enables users to quickly identify hazards. The digital twin system significantly improves safety through real-time leak detection and automatic alerts, increases efficiency by optimizing energy consumption and refuelling processes, and enhances reliability through predictive maintenance. However, widespread adoption of this technology faces challenges including managing large volumes of data, accurately modelling complex processes, and implementing effective solutions. Future development directions include integrating quantum computing, deploying advanced sensor systems, and leveraging artificial intelligence, which together may contribute to developing safer and more sustainable hydrogen infrastructure.

• Periodical: Advances in Science and Technology (Volume 181)
• Pages: 329-338
• DOI: https://doi.org/10.4028/p-E7rALv
• Online since: August 2026
• Authors: Gabor Hasulyo*, Marianna Vadászi
• Keywords: Hydrogen, Hydrogen Economy, Refuelling Station, Virtual Model

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