Liquid hydrogen refueling stations: A review on process layouts, pump technology, and cold energy utilization

Liquid hydrogen (LH₂) storage and gaseous hydrogen (GH₂) refueling stations have gained significant attention due to the lower energy consumption and cost of LH₂ storage and transportation compared to GH₂. However, a comprehensive review of the historical development and future trends of liquid hydrogen refueling station (LHRS) process layouts remains lacking, particularly from the perspectives of energy consumption and refueling costs. In addition, the core equipment unique to LHRSs—the LH₂ pump—has not been systematically analyzed regarding factors affecting its stable operation. Moreover, there is no structured review on the utilization of cold energy released during LH₂ vaporization. To address these gaps, this paper first examines the economic advantages of LH₂ storage and transportation. Based on this foundation, it systematically categorizes LHRS process layouts according to different pressurization methods. The energy consumption of each pressurization strategy is compared, and the composition of refueling costs is analyzed. Notably, the LH₂ pump contributes approximately 20 % of the total investment cost and 25 % of the operational cost. Subsequently, this study focuses on LH₂ pump technology, identifying key factors that influence its stable operation and proposing corresponding management strategies. Finally, recent advancements in LH₂ cold energy utilization are reviewed. Key challenges hindering its widespread application are discussed, along with the impact of policies on the large-scale deployment of LHRSs.