How to Calculate Hydrogen Refueling Station Throughput
Hydrogen refueling stations must deliver predictable daily throughput to justify capital spending and to meet fleet availability commitments. Because dispenser hardware, pre-cooler performance, and cascade storage interact, planners often misjudge how many kilograms per day a site can actually provide. A consistent calculation aligns engineering assumptions with commercial forecasts.
This guide lays out a structured method to estimate throughput. We define the input variables, walk through the underlying equations, and describe validation routines that reconcile the calculation with station telemetry. The workflow complements queue management in the hydrogen fueling queue delay calculator and inventory swing modelling in the linepack flexibility walkthrough.
Definition and planning context
Throughput describes how many kilograms of hydrogen the station dispenses per day under typical operating conditions. It is driven by three levers: the number of dispensers available, the average time to complete a fill, and the number of hours per day that dispensing operations remain open. Availability adjustments account for maintenance, storage depletion, and other derates.
Fleet operators use throughput to size fuel supply contracts, to set service level agreements, and to validate whether distributed stations can cover peak demand. Developers rely on the same calculation when evaluating cascade storage, compressor sizing, and upstream logistics such as tube trailer deliveries or on-site electrolysis.
Variables, units, and assumptions
Collect the following inputs before performing the calculation:
- D – Number of active dispensers (count). Parallel fueling points available during the operating window.
- tfill – Average fill time (minutes). Includes connect, pressurisation, ramp, and disconnect steps.
- H – Operating hours per day (hours). Reflects staffed hours or automation coverage.
- m – Average hydrogen dispensed per vehicle (kilograms).
- α – Operational availability (fraction). Captures downtime from maintenance, storage depletion, or equipment faults.
- Qday – Kilograms dispensed per day.
- Vday – Vehicles served per day.
Availability α defaults to 0.95 in the embedded calculator but should be replaced with empirical reliability data when possible. Treat significant pre-cooler limitations as part of tfill or α to avoid overstating throughput.
Throughput equations
The deterministic equations rely on unit conversions between minutes and hours:
Fills per day = (D × H × 60 × α) ÷ tfill
Qday = Fills per day × m
Vehicles per hour = Fills per day ÷ H
Qhour = Qday ÷ H
If α is unknown, assume 90–95% for modern stations that experience occasional dispenser lockouts or cascade rebalancing. For early pilots or sites with frequent trailer swaps, degrade α further to capture realistic downtime. Always record the source of the availability assumption so operations teams can update it when telemetry improves.
Step-by-step calculation process
1. Profile dispenser availability
Document how many dispensers are operational simultaneously. In multi-island layouts, consider maintenance and staffing limits that may cap concurrent service below the hardware nameplate. Track historical faults to refine α.
2. Measure fill durations
Use transaction logs or stopwatch studies to capture the full time per fill. Include connection, communication handshake, pre-cooling, pressure ramp, and disconnect. Separate metrics for light-duty and heavy-duty vehicles if both are served.
3. Confirm operating hours
Count the hours each day the station dispenses hydrogen. For 24/7 operations with overlapping maintenance, adjust α rather than H to account for partial downtime. For stations that shut down overnight, use the staffed window only.
4. Estimate kilograms per vehicle
Review fleet telematics or dispenser logs to determine the typical hydrogen amount per transaction. Light-duty passenger cars average 4–6 kg; heavy-duty trucks range from 25–40 kg. Weighted averages should match the expected vehicle mix.
5. Calculate throughput and vehicles served
Apply the equations to produce Qday, Qhour, and Vday. Compare results to contract requirements or to hydrogen supply constraints to identify bottlenecks.
Validation and stress testing
Validate the model by reconciling calculated throughput with metered dispenser data. Plot hourly kg dispensed and compare to Qhour. Large variances may indicate conservative fill time assumptions or unaccounted reliability events. Use the cavern cushion gas guide when upstream storage buffers limit flow.
Stress-test the calculation by simulating peak demand days. Reduce α to reflect potential compressor faults or apply longer tfill when ambient conditions challenge pre-cooling. Document the sensitivity so planners can design redundant equipment or demand management tactics.
Limitations and interpretation
The equations assume each dispenser draws from a common supply that can sustain the required mass flow. If cascade storage or electrolysers cannot replenish quickly enough, throughput will be constrained before the dispenser calculation. Incorporate upstream bottlenecks explicitly in project feasibility studies.
Likewise, the model treats fill time as a fixed average. Real-world operations experience variability driven by state of charge, ambient temperature, and communication retries. Monitor distributions rather than just averages when setting service guarantees.
Embed: Hydrogen refueling station throughput calculator
Enter dispenser count, fill time, operating hours, and per-vehicle mass to estimate kilograms per day and vehicle throughput with availability adjustments.