High-pressure technology for hydrogen

The sustainable and secure supply of clean energy to our society is one of the greatestchallenges of our time. Hydrogen combines energy security, climate neutrality and, as anenergy carrier, has extraordinary potential to make a significant contribution to the energy transition.

If hydrogen is produced by electrolysis at low pressure (e.g. approx. 8 - 40 bar) it must be compressed to the highest possible pressure level for storage. For example, long-term storage tanks (home power solutions) are filled or forklift trucks, drones, pilot vehicles such as buses and cars are supplied with hydrogen. However, high-pressure hydrogen is also required for recovery applications, laboratory applications and other power-to-gas applications.

Areas of application for the HULC

• Filling long-term storage tanks (Home Power Solutions)
• Hydrogen compression for forklift trucks and pilot vehicles such as buses and cars
• Laboratory applications that require the highest pressures and cost-effective solutions
• Hydrogen supply for drones
• Various power-to-gas applications
• Hydrogen compression for the supply of project sites that are difficult to access / autonomous energy supply
• Pressurisation for tests with e.g. forming gas (95% nitrogen and 5% hydrogen)

Flex Drive - Market-driven innovation

An important contribution to the sustainability of technical solutions is the implementation of energy-efficient measures.With this in mind and supported by market feedback and customer surveys, we have developed various product-related optimizations. The unique and patented Flex-Drive technology for our pneumatically operated gas compressors with two air drive sections is one of these optimizations to achieve ecologically efficiency-enhancing goals.

With Flex Drive technology, we offer our customers a unique opportunity to get the most out of their high-pressure technology in terms of efficiency. The technology allows the two air drive parts to be pressurized independently of each other and therefore only one of the two compressed air drives to be used when the power requirement is low (principle of the area ratio drive section vs. high-pressure section).

This is particularly advantageous when filling large storage tanks over long periods of time or in the process of initially low-pressure relevant volume flows. When a certain pressure level (Flex pressure) is reached and one air drive section is no longer sufficient to supply a constant volume flow or pressure, the second air drive automatically switches on.

• Patented FlexDrive technology: Save up to 40% compressed air (BAFA eligible)
• Optionally available for all Hulc modules
• Time savings of up to 20% can be achieved in applications for filling storage tanks

Modular compressor solution for hydrogen

A standard configuration up to 1,050 bar consists of one control module (MASTER-module) and up to four gas booster modules (X-modules) - first stage module up to 90 bar, second stage module up to 300 bar, the third stage module up to 600 bar and the final stage module up to 1,050 bar. This configuration will provide a gas outlet flow of 2,5 kg Hydrogen per hour (average). For higher outlet capacities more modules can be connected easily.

This complete series is installed in 19“ rack frame with front panel mounting and front connection for easy installation, exchange and access. This system can be easy installed and combined.

For all applications the MASTER module is mandatory and is handling safety and functional features for maximum four X-modules. The X-modules can be combined and connected depending on the application.

• 1 master module can control up to 4 compressor modules
• Similar modules can be connected in series to achieve the highest pressures or in parallel to achieve the highest flow rates
• The complete solution is set up in 19“ racks in different heights (S and L)
• The maximum pressure level is 1,050 bar and up to a maximum of 2.5 kg of hydrogen per hour can be compressed (at 300 bar inlet pressure and 1,050 bar outlet pressure) as well as the parallel operation of two modules
• The minimum inlet pressure is 8 bar, the maximum inlet pressure is 300 bar (this means that the system can be used with almost any PEM/AEM electrolyser and also bundle accumulators up to 300 bar).
• All hydrogen-carrying high-pressure lines are equipped with our proven cone and thread fittings.
• High-pressure gas filter in each stage (7μm) for maximum purity
• Integrated cooling for maximum efficiency (no additional energy required)
• The system has no electrical connection (power supply), it is a purely mechanical system
• Each module is equipped with a stroke counter for easy lifetime monitoring
• Complete machine according to ATEX Zone 2 and Machinery Directive