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 carbon-neutral way.

While environmentally 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 on a large-scale in an environmentally friendly way via electrolysis both represent uncharted territory. Electrolysis plays a key role here, as hydrogen generated using carbon-neutral methods serves as a fuel for mobility, an energy source for the supply of 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 environmentally friendly way.

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

Components and systems for battery storage systems

The storage of electricity will play a major role in the future of the power grid as the percentage of renewable energy continues to increase.  Battery storage systems  are increasingly being used to rapidly balance out power generation and power consumption (grid regulation). For example, power plant operators can use the storage for grid stabilisation and to run their power plants more smoothly. Industrial companies can use the systems to provide uninterrupted power supply, increase their internal consumption from photovoltaic plants installedand smooth out load peaks ( "peak shaving"). In the context of quick charging stations for battery-powered vehicles, battery storage systems can be used to reduce the high peaks that strain the power grid during charging, avoiding an expensive grid expansion.

Regardless of the particular application, we're your contact for fluid cooling in terms of battery modules and the associated converters that are needed for the grid connection. For this purpose, we provide compressor cooling systems (chillers), 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 carbon-neutral way. If this is the case, it forms the basis of many sectors of industry as well as heavy-load mobility. Using electricity, for example 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 alkaline, PEM and SOFC electrolysis. HYDAC supplies an extensive portfolio of components and systems for all three technologies.

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

Both 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 implemented using innovative products from HYDAC process technology .

With expertise in cooling systems, heat exchangers and separators/filtration , HYDAC can provide innovative system solutions for hydrogen and oxygen condensation drying. 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 of 16 to 1050 bar .

Tried-and-tested mounting systems from HYDAC Accessories make it possible to mount power cables and hydrogen containers quickly and securely, in little space.

Modular cooling systems

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

Tailor-made cooling systems for integration into system setups and containers. E.g. the  cooling box can be used as a central cooling solution for multi-MW systems.

Plate heat exchangers

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

Particle filters and fluid separators for hydrogen

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

Development partner for hydrogen valve technology

Exciting challenges around the topic of hydrogen also await you in the valve technology industry. With almost 50 years of experience in the development and manufacture of valves, we're already working on custom solutions. Get in touch with us – we look forward to working with you on a joint project!

Components and systems for fuel cell power plants

Hydrogen and fuel cells will play an important role in the future of sustainable energy supply. 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 its use as an 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, fuel cells 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, both for mobile and stationary use, to complex cooling systems with DI water circuits.

Modular cooling systems

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

Mounting technology - mounting technology for tank systems

To transport the hydrogen needed for the fuel cells , type 3 or type 4 containers are currently used, 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. Using our unique flexible stainless steel straps with patented quick release bolts combined with custom-developed neck mounts , we can implement mounting systems that allow the containers to expand and contract while keeping them held secure in the event of impact. Thanks to our many years of 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 solution for your tank system mounting.

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 filter design provides the 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. The differential pressure stability and resistance to pressure surges are excellent due to the extremely robust and resistant technology. The applications for our filters can be found throughout the hydrogen cycle, from systems for hydrogen production (e.g. electrolysers) to systems for hydrogen filling stations and even test benches for hydrogen system components.

Pressure sensors for hydrogen

With over 30 years of experience in developing and producing pressure sensors HYDAC Electronic has established a new series of hydrogen sensors on the market. Thanks to HYDAC’s in-house manufacture of the pressure measurement cells, 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) .

The applications for our stationary sensors can be found throughout the hydrogen cycle, from systems for hydrogen production (e.g. electrolysers) to systems for hydrogen filling stations  and even test benches for hydrogen system components.

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