Machines and vehicles being powered by either electric batteries or hydrogen only makes sense from a climate protection perspective if the electricity and hydrogen used can be made available in a CO2-neutral way.

While climate-friendly power generation with wind power and solar power plants is already an established industry outside of electromobility, using stationary battery storage to level out fluctuations in the generation of renewable energy and generating hydrogen by means of electrolysis on a large-scale in an environmentally friendly way both represent uncharted territory. Electrolysis plays a key role here, as hydrogen generated using CO2-neutral methods serves as a fuel for mobility, an energy source for supplying electricity and heat, a substitute material in industrial processes such as steel production and a raw material in the chemicals industry. Fuel cell power plants make it possible to supply electricity and heat to households and industrial companies in a safe and climate-friendly way.

HYDAC products for these applications cover cooling systems for battery storage, fuel cell power plants and electrolysis systems, sensors and filtration solutions for hydrogen applications and mounting technology for power cables and hydrogen tanks.

Components and systems for battery storage

The storage of electricity will play a major role in the future mains power supply, as the percentage of renewable energy continues to increase. To rapidly balance out power generation and power consumption (grid stabilisation), battery storage is increasingly being used. Power plant operators can, for example, use the storage for grid stabilisation and at the same time run their power plants more smoothly. Industrial companies can use the systems both to provide uninterrupted power supplyand to increase their internal consumption from installed photovoltaic plantsand smooth out load peaks ( “peak shaving”) in order to lower the costs for their electricity supply. In the context of quick charging stations for battery-powered vehicles, battery storage can be used to reduce the high peaks that strain the power grid during charging and thus avoid an expensive grid expansion.

Regardless of the particular application, we are your contact for the fluid-cooling of battery modules and of the associated frequency converters that are needed for the grid connection. We can provide compressor cooling systems (chillers) and fluid/air cooling systems, plate heat exchangers and liquid cold plates.

Components and systems for electrolysis plants

Hydrogen can only help with decarbonisation if it is generated in a CO2 -neutral way. If it is, however, it forms the foundation of decarbonisation for many sectors of industry and heavy-load mobility. Using electricity from renewable energy sources (wind, sun, water) to split up water into its constituent parts is referred to as electrolysis . Electrolysis systems can be based on alkali, PEM or SOFC electrolysis. HYDAC supplies an extensive portfolio of components and systems for all three technologies.

Despite the plants’ high efficiency, large amounts of heat need to be dissipated because of the high levels of installed power. To assist with this, we supply modular, high-performance coolers and cooling systems for electrolysis stacks and rectifiers

The treatment and filtration of the process fluids (de-ionised water or potassium hydroxide solution)that are split up into hydrogen and oxygen in the electrolyser and the release of the product gases hydrogen and oxygen from the residues of these process fluids can be realised by means of innovative products from HYDAC process technology .

With expertise in cooling systems, heat exchangers and separators/filtration, HYDAC can provide innovative system solutions for the condensation drying of hydrogen and oxygen. This involves using heat exchangers with a connected cooling system to cool down the product gases so that the water they contain can be condensed out and removed by a separator.

On the hydrogen side, there is also an extensive portfolio of pressure sensorswith nominal pressures from 16 to 1050 bar .

Well-established mounting systems from HYDAC Accessories make it possible to mount power cables and hydrogen containersquickly and securely, in little space.

Modular cooling systems

Modular table coolers with microchannel heat exchanger elementsthat have been optimised for low-temperature cooling by means of water-glycol. All coolers are available in a range of designs, e.g. also in low-noise or heavy-duty versions.

Tailored cooling systems for integration in system set-ups and containers. e.g. Cooling box as central cooling solution in multi-MW systems.

Plate heat exchangers

Nickel-brazed stainless steel plate heat exchangers  for cooling the process fluids and the gases generated (oxygen and hydrogen)

Particle filters and fluid separators for hydrogen

Customised and standard combinations of cyclone separators and coalescence filter elements for separating hydrogen and oxygen from DI water or KOH lye.

Components and systems for fuel cell power plants

Hydrogen and fuel cells will play an important role in sustainable power supply in the future. Fuel cells are electrochemical energy converters that convert hydrogen, natural gas, biogas, liquid gas or other fluid fuels directly into electricity and heat. They are not, however, energy storage systems, like batteries. Instead, they need an external supply of fuel (e.g. from a fuel tank or a connected gas line). The decentralised supply of power with fuel cells,in particular to commercial and industrial facilities, and the use as emergency power supply for hospitals, computer centres, processes in food supply etc. already play a major role. Another application is the generation of power in remote locations where no grid connection is available, or where a connection is not economically or technically feasible. Using pure hydrogen for stationary applications is already providing opportunities for generating electricity and heat inexpensively. In stationary fuel cell power plants, fuels with SOFC, MCFC and PEMFC technology are increasingly being used. For all technologies, HYDAC provides an extensive portfolio of components and systems, ranging from tank mounting systems, filtration and sensors, for both mobile and stationary use, to complex cooling systems with DI-water circuits.

Modular cooling systems

Modular table coolers with microchannel heat exchanger elements for cooling stationary fuel cells that have been optimised for low-temperature cooling by means of water-glycol. All coolers are available in a range of designs, e.g. also in low-noise or heavy-duty versions. Coolers that are compatible with DI-water are also possible.

Mounting technology for tank systems

The fuel cells need hydrogen , which is currently transported by type-3 or type-4 containers, depending on the application. Type-4 containers (carbon fibres wrapped around a plastic reel) in particular undergo considerable changes in their length and diameter during operation. With our unique flexible stainless steel straps with patented quick release bolts combined with individually developed neck mounts, we can realise mounting systems that allow the containers to expand and contract while keeping them securely held in the event of impact. Thanks to our extensive experience as one of the leading companies in the engineering and supply of mounting systems for CNG and hydrogen containers made from composite materials, we can work with you to find the best possible solutions for the mounting of your tank system.

Particle filters and fluid separators for hydrogen

With the GF/GCF filter series, HYDAC is offering the leading technology for filtering gases in hydrogen applications up to 1,050 bar. The design of the filters provides maximum filter area in the most compact dimensions and is noted for excellent process stability, top quality permeate and minimal pressure loss . The Chemicron® filter material developed by HYDAC exclusively for gas applications provides defined separation rates with maximum filter integrity. The stainless steel filter elements are manufactured entirely without the use of resins which means they can be used at extreme temperatures and with particularly aggressive media. On account of the extremely robust and resistant technology, the differential pressure stability and resistance to pressure surges are excellent. The applications for our filters can be found throughout the hydrogen cycle, beginning with systems for hydrogen production (i.e. electrolysers) through to systems for hydrogen filling stations, but also in test benches for hydrogen system components.

Pressure sensors for hydrogen

With over 30 years of experience in pressure sensor development and production, HYDAC Electronic has established a new series of hydrogen pressure sensors on the market. Thanks to HYDAC’s in-house manufacture of the pressure measurement cell, it was possible to develop a hydrogen cell based on stainless steel. The sensors are based on a robust, long-life sensor cell with a thin-film strain gauge on a stainless steel membrane. The sensor cell is welded to the process connection – there are no internal seals. The compatibility with hydrogen is ensured by using a particular material. The pressure sensors are now used worldwide in fuel cell vehicles (with EC79/2009 certification) and stationary applications (ATEX, IECEX, CSAUS) worldwide .

The applications for our stationary sensors can be found throughout the hydrogen cycle, beginning with systems for hydrogen production (i.e. electrolysers) through to systems for hydrogen filling stations, but also in test benches for hydrogen system components.

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