Numerical simulation of hydrogen filling in a Type III tank: A case study for Casablanca, Morocco

This study numerically investigates the fast-filling process of a Type III 74 L hydrogen tank under Casablanca, Morocco climatic conditions (Tₐₘₗ = 33°C) using a 2D axisymmetric CFD model solved with ANSYS Fluent. The Standard k-ε turbulence model and the Redlich-Kwong real gas equation of state are employed, with constant solid-phase properties and temperature-dependent hydrogen thermophysical properties. The impact of varying mass flow rates (4–12 g/s) on temperature evolution and storage efficiency is analyzed. Results identify an optimal flow rate of 10 g/s, maximizing stored mass (1550 g) while maintaining temperature below the 85°C safety limit. At 12 g/s, the safety threshold is reached prematurely, terminating the filling process and reducing the stored mass to 1272 g. A seasonal comparison shows that summer conditions reduce storage capacity by 42% versus winter, causing a 53% revenue loss per transaction. The influence of pre-cooling and forced convection is discussed as a perspective for future work. These findings provide a basis for adaptive, climate-resilient refueling protocols applicable to Casablanca and similar hot-climate cities.