HYDAC's hydrogen solutions

The production, supply and use of hydrogen has enormous potential for an emissions-free future, but there are still challenges to be overcome.

We have a long way to go before all the questions on the topic of hydrogen are answered. This is because the production, supply and use of hydrogen still poses challenges for companies. But one thing is certain: hydrogen and alternative energy sources in mobile and industrial solutions have enormous potential for an environmentally friendly and emissions-free future in households, industries and transport.

But the topic of hydrogen quickly becomes complex. That’s why it pays to have an expert at your side who offers innovative approaches to solutions while bringing tried-and-tested products and decades of industry know-how to the table. Whether it’s a new development or series production — HYDAC will help you with the successful integration of systems in your project.

Hydrogen purity

High-purity hydrogen is required for some applications, but the raw gas product hydrogen is often contaminated with impurities from water and oxygen after production. DIN EN 17124 specifies that these impurities must be less than 5 ppm. With our innovative hydrogen drying, we can reach higher hydrogen qualities than the standard requires when necessary.

Hydrogen filtration program

HYDAC has the following products on offer for its hydrogen filtration program: the GF1 gas filter, the GF3 gas filter, the GCF gas coalescer filter, and the GFH gas particle filter.

Technical specifications for these products span pressures of 16 bar to 1,050 bar; flow rates of 60 g/s to 150 g/s and 1 kg/s to 160 kg/s; and filtration ratings of 0.3 µm to 250 µm.

The stainless steel filter elements come in HYDAC’s patented Chemicron, which features no electrostatic charging; a pleated filter design that allows for maximum filtration area for optimal dirt-holding capacity; no fibre migration on the surface; and a graduated filter structure for maximum filter porosity to ensure the lowest pressure loss.

“The design of the GF1 offers the maximum filtration area in the most compact dimensions. The extremely robust stainless steel filter elements are noted for their outstanding differential pressure stability and resistance to pressure surges,” said HYDAC’s National Development Manager for E-Mobility & Hydrogen Systems.

“The Chemicron metal fibre fleece developed by HYDAC delivers defined filtration rates and maximum filter integrity. The combination of different filter layers prevents perforation of the filter material.

“No resins at all are used in the construction of the filter element. This means that electrostatic charging is avoided and operation with aggressive media subject to extreme temperature fluctuations is possible.”

Hydrogen compression and cooling

Compared to gaseous hydrogen storage, liquid hydrogen as a fuel offers advantages in terms of energy density (71 kg/m³). The pressure in the tank can also be kept low. This has a positive effect on the tank system in terms of the storage tank weight and space requirements, costs (especially for large storage volumes) and safety.

But the production costs of cryogenic hydrogen (-253°C) are not insignificant. The hydrogen also heats up if it is not constantly cooled. This leads to an increase in pressure within the tank, which can lead to the gaseous hydrogen being vented into the environment.

Hydraulic power units

HYDAC’s hydraulic power units for hydrogen compression have the following advantages: an innovative filter concept for a dramatically reduced hydraulic tank; a load-sensing principle for high energy efficiency; intelligent cooling and heating for reduced energy consumption; and a modular building block system design for reduced design effort.

Cooling systems for hydrogen compression

The company’s cooling systems for gas compressors are used to cool hydraulic power units, piston heads and compressed hydrogen.

ATEX-approved and compact water glycol circuits, with a wholly redundant pump unit, offer improved performance at the lowest noise level in an innovate pump-block solution, which is almost maintenance free.

Pressure transmitters

HYDAC’s pressure transmitter series for hydrogen applications are based on a robust and long-life thin-film sensor cell, which is welded onto the process connection, eliminating the requirement for seals within the fluid port connection. All parts in contact with the hydrogen are constructed out of approved stainless steel.

HYDAC has on offer a range of pressure transmitters from the HDA 4400 series for use in industrial hydrogen applications such as hydrogen compressors and dispensers. These transmitters are approved for a variety of hydrogen applications in explosive atmosphere, which enables almost global use of this product range.

A double-approval version with ATEX and IECEx has been developed with ignition protection types ‘intrinsically safe’ and ‘non-incendive’. These devices are also available as a redundant version for implementing into systems requiring increased functional safety.