The engineering correlations for assessment of hazard distance defined by a size of fireball after either liquid hydrogen spill combustion or high-pressure hydrogen tank rupture in a fire in the open atmosphere (both for stand-alone and under-vehicle tanks) are presented. The term “fireball size” is used for the maximum horizontal size of a fireball that is different from the term “fireball diameter” applied to spherical or semi-spherical shape fireballs. There are different reasons for a fireball to deviate from a spherical shape, e.g., in case of tank rupture under a vehicle, the non-instantaneous opening of tank walls, etc. Two conservative correlations are built using theoretical analysis, numerical simulations, and experimental data available in the literature. The theoretical model for hydrogen fireball size assumes complete isobaric combustion of hydrogen in air and presumes its hemispherical shape as observed in the experiments and the simulations for tank rupturing at the ground level. The dependence of the fireball size on hydrogen mass and fireball’s diameter-to-height ratio is discussed. The correlation for liquid hydrogen release fireball is based on the experiments by Zabetakis (1964). The correlations can be applied as engineering tools to access hazard distances for scenarios of liquid or gaseous hydrogen storage tank rupture in a fire in the open atmosphere.

A hydrogen under-expanded jet released from a high-pressure vessel or equipment into the atmosphere through a 0.53 mm diameter orifice results in a sustained lifted flame for pressures above 4 MPa and flame blow-out at pressures below 3 MPa. Knowledge of whether the leaked hydrogen creates a sustained flame or is extinguished is an important issue for safety engineering. This study aims to clarify, in detail, a mechanism of flame stabilisation and blow-out depending on the spouting pressure. The model of flame stabilisation is derived using measurements and observations at the flame base location by means of high-speed schlieren images, laser diagnostics, and electrostatic probe techniques. The sustained stable flame originating from the 0.53 mm orifice is characterised by the existence of the spherical flame structures with a diameter of about 5 to 7 mm that appear one after another at the flame base and outside the streamlines of the hydrogen jet. As the spouting pressure reduces to 3.5 MPa, the sustained lifted flame becomes quasi-steady with higher fluctuations in amplitude of the flame base (lift-off height). In addition to that, flame structures are moving further from the hydrogen jet outlet, with a further decrease of spouting pressure leading to blow-out. The existence of spherical flame formations plays an important role in flame stabilisation. Based on the measurements of OH radicals using the PLIF method and ion currents, multiple flame surfaces were found to be folded in the flame structures. The hydrogen jet generates the vortex-like flow near its outer edge, creating flamelets upon ignition, ultimately forming the observed in the experiments spherical flame structures.

In the present study, pilot simulations of the phenomena of blast wave and fireball generated by the rupture of a high-pressure (35 MPa) hydrogen tank (volume 72 L) due to fire were carried out. The computational fluid dynamics (CFD) model includes the realizable k-ε model for turbulence and the eddy dissipation model coupled with the one-step chemical reaction mechanism for combustion. The simulation results were compared with experimental data on a stand-alone hydrogen tank rupture in a bonfire test. The simulations provided insights into the interaction between the blast wave propagation and combustion process. The simulated blast wave decay is approximately identical to the experimental data concerning pressure at various distances. Fireball is first ignited at the ground level, which is considered to be due to stagnation flow conditions. Subsequently, the flame propagates toward the interface between hydrogen and air.

This paper presents a review of explosion mitigation techniques for road tunnels, with a focus on scenarios involving high-pressure hydrogen tank rupture under fire conditions. Both passive and active strategies are considered—including structural configurations (e.g., tunnel branching, vent openings, right-angle bends) and protective systems (e.g., drop-down perforated plates, high-performance fibre-reinforced cementitious composite (HPFRCC) panels)—to reduce blast impact on tunnel occupants and structures. The review highlights that while measures such as blast walls or energy-absorbing barriers can significantly attenuate blast pressures, an integrated approach addressing both blast load reduction and structural resilience is essential. This paper outlines how coupled computational fluid dynamics–finite element method (CFD–FEM) simulations can evaluate these mitigation methods, and we discuss design considerations (e.g., optimising barrier placement and tunnel geometry) for enhanced safety. The findings provide guidance for designing safer hydrogen vehicle tunnels, and they identify gaps for future research, including the need for experimental validation of combined CFD–FEM models in hydrogen fire–explosion scenarios.