MC Formula Protocol for H35HF Fueling Cooperative Research and Development Final Report

Summary

This final report details a Cooperative Research and Development Agreement (CRADA CRD-20-17412) between NREL and Frontier Energy to develop an H35 high-flow (HF) fueling protocol for medium-duty (MD) and heavy-duty (HD) vehicles. The project involved upgrading NREL's H2FillS model to generate MC Formula fueling tables using high-performance computing, with an estimated NREL in-kind contribution of $545,500 over two years. Key boundary conditions were defined, targeting a fueling time of under 15 minutes and a peak mass flow rate of 120 g/s, with onboard storage systems up to 70 kg. The generated fueling tables were validated through extensive simulations and physical experiments at NREL and ZBT, confirming that hydrogen temperatures in vehicle tanks did not exceed the 85°C safety limit, even with fueling times around 200 seconds. The validated protocol was incorporated into the SAE J2601-5 TIR published in February 2024, and an H2FillS model upgrade and a protocol validation calculator are expected for public release by December 2024.

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