alternativeАльтернативная энергетика и экология (ISJAEE)Alternative Energy and Ecology (ISJAEE)1608-8298Международный издательский дом научной периодики "Спейс10.15518/isjaee.2025.12.018-039alternative-2747Research ArticleIV. ВОДОРОДНАЯ ЭКОНОМИКА 12. Водородная экономика 12-11-0-0 Водородные автозаправочные станцииIV. HYDROGEN ECONOMY 12. Hydrogen economy 12-11-0-0 Hydrogen filling stationsБезопасность как фактор технологического развития водородной заправочной инфраструктурыSafety as a driver of technological development in hydrogen refueling stations infrastructurehttps://orcid.org/0000-0001-7749-8482ФроловаЕ. А.FrolovaE. A.

Фролова Елена Александровна, кандидат физико-математических наук, Руководитель проекта Центра компетенций технологического развития ТЭК при Министерстве энергетики Российской Федерации; Эксперт / руководитель проекта ФГБУ «Российское энергетическое агентство» Минэнерго РФ / АО «Центр эксплуатационных услуг»

121099, Москва, Новинский бульвар, д. 13, стр. 4

127083, г. Москва, ул. 8 Марта, д. 12

Web of Science Researcher ID: ADO-6430-2022

Scopus Author ID: 57201385755

Frolova Elena Alexandrovna, PhD in Physics and Mathematics, Project Manager of the Competence Centre for Technological Development of the Fuel and Energy Complex of the Ministry of Energy of the Russian Federation; Expert / Project Manager, Federal State Budgetary Institution «Russian Energy Agency» of the Ministry of Energy of the Russian Federation / JSC «Center for Operational Services»

121099, Moscow, Novinsky Boulevard, 13, Building 4

127083, Moscow, 8 Marta Street, 12

Web of Science Researcher ID: ADO-6430-2022

Scopus Author ID: 57201385755

https://orcid.org/0000-0002-5287-4397ЖданеевО. В.ZhdaneevO. V.

Жданеев Олег Валерьевич, доктор технических наук, ведущий научный сотрудник Федеральное государственное бюджетное учреждение науки Ордена Трудового Красного Знамени Институт нефтехимического синтеза им. А. В. Топчиева Российской академии наук (ИНХС РАН); Профессор высшей нефтяной школы, Югорский государственный университет; Советник генерального директора/Старший советник генерального директора ФГБУ «Российское энергетическое агентство» Минэнерго РФ/ АО «Центр эксплуатационных услуг»

119991, Москва, Ленинский проспект, 29

420008, РТ, г. Казань, ул. Кремлевская, д. 18

103274, г. Москва, Краснопресненская набережная, дом 2

Web of Science Researcher ID: AAP-1159-2020

Scopus Author ID: 6603132551

Zhdaneev Oleg Valerevich, Doctor of Technical Sciences, Leading Researcher Topchiev Institute of Petrochemical Synthesis, Russian Academy of Sciences (INHS RAS); Professor of the Higher Oil School, Yugra State University; Advisor to the General Director/Senior Advisor to the General Director of the Federal State Budgetary Institution «Russian Energy Agency» of the Ministry of Energy of the Russian Federation/ JSC «Center for Operational Services»

119991, Moscow, Leninsky avenue, 29

420008, RT, Kazan, Kremlevskaya Street, 18

103274, Moscow, Krasnopresnenskaya Embankment, 2

Web of Science Researcher ID: AAP-1159-2020

Scopus Author ID: 6603132551

Zhdaneev@rosenergo.gov.ruЦентр компетенций технологического развития топливно-энергетического комплекса при Минэнерго России; ФГБУ «Российское энергетического агентство» Минэнерго РоссииРоссияCenter for Competencies in Technological Development of the Fuel and Energy Complex under the Ministry of Energy of the Russian Federation; Russian Energy Agency, Ministry of Energy of the Russian FederationRussian FederationИнститут нефтехимического синтеза им. А. В. Топчиева РАН; Казанский (Приволжский) федеральный университет; Российская академия народного хозяйства и государственной службы при Президенте Российской ФедерацииРоссияA. V. Topchiev Institute of Petrochemical Synthesis, RAS; Kazan (Volga Region) Federal University; Russian Presidential Academy of National Economy and Public Administration under the President of the Russian FederationRussian Federation2025190220260121839Copyright © Международный издательский дом научной периодики "Спейс, 20262026Международный издательский дом научной периодики "СпейсМеждународный издательский дом научной периодики "Спейсhttps://www.isjaee.com/jour/about/submissions#copyrightNoticehttps://www.isjaee.com/jour/article/view/2747

    В настоящей работе выполнен системный инженерный анализ конфигураций водородных заправочных станций (ВЗС) с целью выявления факторов, определяющих надёжность, безопасность, энергетическую эффективность и целесообразность применения различных архитектур в регионально неоднородных условиях эксплуатации. Исследование основано на данных реальной эксплуатации водородных станций, результатах демонстрационных и коммерческих проектов, а также обобщении рецензируемой научной и технической литературы.    Показано, что ключевые проблемы развития ВЗС носят преимущественно инженерный характер и связаны не с принципиальной реализуемостью технологий, а с эксплуатационной устойчивостью оборудования, высокой энергоёмкостью технологических операций и деградацией материалов в условиях циклических нагрузок и высоких давлений. Анализ отказов и показателей эксплуатационной доступности выявил, что компрессорные системы высокого давления, заправочные диспенсеры и подсистемы управления формируют основную долю внеплановых остановок станций. Характер отказов тесно связан с режимами циклирования давления и температуры, что подчёркивает определяющую роль усталостных процессов, термомеханической деградации и водородного охрупчивания металлических компонентов.    Установлено, что процессы компримирования, предохлаждения и хранения водорода формируют до 40% совокупного энергопотребления ВЗС, существенно влияя на эксплуатационные затраты и экономическую эффективность инфраструктуры. Анализ современных инженерных решений показывает, что оптимизация протоколов заправки и управление каскадными системами хранения позволяют снизить удельную энергоёмкость процесса заправки на 9-45% в зависимости от интенсивности эксплуатации станции. При этом наибольший эффект достигается при согласовании режимов работы компрессоров и систем охлаждения с фактическим профилем спроса.    Особое внимание в работе уделено мерам повышения надёжности ВЗС. Показано, что применение принципов модульности и резервирования критических подсистем, прежде всего компрессорных модулей и систем предохлаждения, позволяет снизить вероятность полной остановки станции на 30-50% при отказе отдельных компонентов. В сочетании с предиктивным техническим обслуживанием, основанным на мониторинге давления, температуры, вибраций и утечек, такие решения обеспечивают существенное повышение эксплуатационной устойчивости инфраструктуры. Совокупная реализация указанных мер позволяет увеличить эксплуатационную доступность ВЗС с характерных для станций первого поколения 94-95% до уровней порядка 98-99%, приближаясь к показателям зрелых газотопливных систем.    Материаловедческие аспекты эксплуатации ВЗС рассмотрены на уровне общепринятых физических механизмов водородного охрупчивания и их инженерных последствий. Показано, что выбор аустенитных нержавеющих сталей с оптимизированной микроструктурой, а также применение композитных сосудов высокого давления типа IV при строгом контроле циклов давления и температуры позволяют увеличить ресурс элементов высокого давления в 2-3 раза по сравнению с традиционными решениями.    Существенным результатом работы является разработка классификации инженерных ограничений ВЗС и основанной на ней матрицы принятия решений по распределению типов станций в зависимости от региональных условий эксплуатации. Показано, что попытки применения унифицированных архитектур ВЗС приводят либо к избыточным капитальным затратам, либо к снижению надёжности и доступности инфраструктуры. Выбор типа станции должен дифференцироваться по региональным условиям с учётом профиля спроса, логистики водорода, энергетической инфраструктуры, климатических факторов и квалификации персонала.    На основе проведённого анализа сформирована поэтапная инженерная «дорожная карта» повышения технической зрелости ВЗС: от краткосрочных эксплуатационных улучшений и оптимизации режимов работы оборудования до долгосрочного перехода к концепции «умных» ВЗС с использованием цифровых двойников и адаптивного управления. Показано, что эволюционный подход позволяет обеспечить одновременное повышение надёжности, безопасности и энергетической эффективности водородной заправочной инфраструктуры без опоры на жёсткую технологическую унификацию.Результаты работы формируют инженерно-обоснованную основу для проектирования, эксплуатации и стратегического планирования водородных заправочных станций и могут быть использованы при разработке нормативных документов и национальных программ развития водородной энергетики.

    This work presents a systematic engineering analysis of configurations of hydrogen refueling stations (HRS) in order to identify the factors that determine the reliability, safety, energy efficiency, and feasibility of using different architectures in regionally heterogeneous operating conditions. The study is based on real-world data from hydrogen stations, the results of demonstration and commercial projects, and a review of peer-reviewed scientific and technical literature.    It has been shown that the key problems of HRS development are predominantly of an engineering nature and are not related to the fundamental feasibility of technologies, but rather to the operational stability of equipment, the high energy intensity of technological operations, and the degradation of materials under cyclic loads and high pressures. An analysis of failures and operational availability indicators has revealed that high-pressure compressor systems, filling dispensers, and control subsystems account for the majority of unscheduled station shutdowns. The nature of failures is closely related to the pressure and temperature cycling modes, which highlights the crucial role of fatigue processes, thermomechanical degradation, and hydrogen embrittlement of metal components.    It has been established that the processes of hydrogen compression, pre-cooling, and storage account for up to 40% of the total energy consumption of gas stations, significantly affecting the operational costs and economic efficiency of the infrastructure. An analysis of modern engineering solutions shows that optimizing refueling protocols and managing cascaded storage systems can reduce the specific energy consumption of the refueling process by 9-45%, depending on the station’s operational intensity. The greatest effect is achieved by aligning the operating modes of compressors and cooling systems with the actual demand profile.    The paper pays special attention to measures to improve the reliability of gas stations. It is shown that the use of modularity principles and redundancy of critical subsystems, primarily compressor modules and pre-cooling systems, can reduce the probability of a complete station shutdown by 30-50% in the event of a failure of individual components. In combination with predictive maintenance based on monitoring of pressure, temperature, vibrations, and leaks, such solutions significantly enhance the operational stability of the infrastructure. The combined implementation of these measures allows for an increase in the operational availability of gas stations from the typical 94-95% for first-generation stations to levels of around 98-99%, approaching the performance of mature gas-fuel systems.    The material science aspects of HRS operation are considered at the level of generally accepted physical mechanisms of hydrogen embrittlement and their engineering consequences. It is shown that the choice of austenitic stainless steels with optimized microstructure, as well as the use of composite high-pressure vessels of type IV, with strict control of pressure and temperature cycles, allow to increase the resource of high-pressure elements by 2-3 times compared to traditional solutions.    A significant result of the work is the development of a classification of engineering constraints for hydrogen stations and a decision-making matrix based on it for distributing station types depending on regional operating conditions. It has been shown that attempts to apply unified hydrogen station architectures lead either to excessive capital costs or to a decrease in the reliability and availability of the infrastructure. The choice of station type should be differentiated based on regional conditions, taking into account the demand profile, hydrogen logistics, energy infrastructure, climate factors, and personnel qualifications.    Based on the analysis, a step-by-step engineering roadmap has been developed to enhance the technical maturity of hydrogen refueling stations, from short-term operational improvements and equipment optimization to the long-term transition to the concept of smart hydrogen refueling stations using digital twins and adaptive control. This evolutionary approach demonstrates how to simultaneously improve the reliability, safety, and energy efficiency of hydrogen refueling infrastructure without relying on rigid technological uniformity.    The results of the work form an engineering-based basis for the design, operation, and strategic planning of hydrogen refueling stations and can be used in the development of regulatory documents and national programs for the development of hydrogen energy.

водородводородные заправочные станцииводородный транспортэнергоэффективностьводородное охрупчиваниеводородная инфраструктура.hydrogenhydrogen refueling stationshydrogen transportenergy efficiencyhydrogen embrittlementhydrogen infrastructure.ReferencesKaplun A. A., Menshikov D. A., Frolova E. A., Zhdaneev O. V. Hydrogen power supply complex for isolated areas // Alternative Energy and Ecology (ISJAEE). 2025; 11:125-143 (in Russian). https://doi.org/10.15518/isjaee.2025.11.125-143Kaplun A. A., Menshikov D. A., Frolova E. A., Zhdaneev O. V. Hydrogen power supply complex for isolated areas // Alternative Energy and Ecology (ISJAEE). 2025; 11:125-143 (in Russian). https://doi.org/10.15518/isjaee.2025.11.125-143Khakimov R., Moskvin A., Zhdaneev O. Hydrogen as a key technology for long-term and seasonal energy storage applications // International Journal of Hydrogen Energy. 2024; 68:374-381. https://doi.org/10.1016/j.ijhydene.2024.04.066Khakimov R., Moskvin A., Zhdaneev O. 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The authors declare that there are no conflicts of interest present.