Hydrogen Refuelling Stations
Your Leading SANY Hydrogen Energy Co., Ltd. Supplier
Focusing on the R&D, manufacturing and sales of hydrogen producing and refueling equipment and key components for a closed-loop full ecological industrial chain featured by green power, hydrogen energy and end-use equipment, SANY Hydrogen Energy Co., Ltd. is the world's leading provider of package solutions for hydrogen energy equipment, which is committed to providing global customers with GW-level ultra-large-scale package solutions on-grid/off-grid hydrogen production from wind and solar energy.
Why Choose Us?
High quality
Our products are manufactured or executed to very high standards, using the finest materials and manufacturing processes.
Competitive Price
We offering a higher-quality product or service at an equivalent price. As a result we have a growing and loyal customer base.
Global shipping
Our products support global shipping and the logistics system is complete, so our customers are all over the world.
Rich experience
Our company has many years of production work experience. The concept of customer-oriented and win-win cooperation makes the company more mature and stronger.
After-sale service
Professional and thoughtful after -sales team, let you worry about us after -sales Intimate service, strong after -sales team support.
Advanced equipment
A machine, tool or instrument designed with advanced technology and functionality to perform highly specific tasks with greater precision, efficiency and reliability.
What is Hydrogen Refuelling Stations？
This infrastructure developed to refill hydrogen is not only for passenger cars, buses, and trucks on public roads, but also for trains and other special vehicles.
Benefits of Hydrogen Refuelling Stations
Clean and environmentally friendly: When hydrogen is used as a fuel, the only byproduct produced is water vapor, making it a clean and emissions-free energy source. This is particularly important in reducing greenhouse gas emissions and combating air pollution, especially in urban areas with high vehicular traffic.
Reduced dependence on fossil fuels: Hydrogen fuel stations promote diversification of the energy mix and reduce dependence on fossil fuels like gasoline and diesel. By using hydrogen as a transportation fuel, countries can decrease their reliance on oil imports, enhancing energy security and reducing vulnerability to oil price fluctuations.
High energy density: Hydrogen has a high energy-to-weight ratio, which means it provides a lot of energy per unit of weight. This characteristic makes hydrogen an attractive option for long-range transportation, where weight considerations are essential.
Quick refueling times: Unlike battery-electric vehicles that require a significant amount of time to recharge, refueling a hydrogen vehicle is relatively quick, similar to refueling a traditional gasoline vehicle. This feature allows for faster turnover and greater convenience for drivers.
Scalability and versatility: Hydrogen can be produced from various sources, such as renewable energy (e.g., wind, solar, and hydro) through electrolysis or from natural gas through steam methane reforming. This versatility in production methods allows for scalability and adaptability to different regions' energy resources and infrastructures.
Long driving range: Hydrogen fuel cell vehicles (FCVs) typically have a longer driving range compared to battery-electric vehicles (BEVs). This makes hydrogen fuel cells a more viable option for heavy-duty and long-haul transportation applications.
Technology advancement and job creation: Investing in hydrogen infrastructure, such as fuel stations, stimulate technological advancements and job creation in related industries, such as hydrogen production, storage, and distribution.
Reduced noise pollution: Hydrogen fuel cell vehicles operate quietly compared to internal combustion engine vehicles, reducing noise pollution in urban areas and promoting a more pleasant urban environment.
Types of Hydrogen Refuelling Stations
At hydrogen stations with liquid storage, a tanker truck pumps hydrogen into an above-ground tank where it’s held at a cryogenic temperature. Liquid hydrogen is vaporized, compressed, and stored in above-ground cylinders for dispensing. As customers fuel their vehicles, the gaseous hydrogen cylinders are refilled. Liquid storage generally requires more space than gaseous storage.
Hydrogen can be delivered as a gas at pressures up to 7,200 psi. Cylinders are mounted into a trailer and the truck driver “refills” the storage by swapping a trailer of full cylinders for a trailer of almost-empty cylinders inside a walled storage area.
Stations can also make hydrogen onsite by electrolysis of water and reforming natural gas or biomethane. At some locations, a station could use hydrogen from an existing pipeline. All three methods result in gaseous hydrogen that must be compressed and stored, and all require more equipment and space than either option for delivered hydrogen. One of the advantages to renewable hydrogen is the future opportunity to sell Low Carbon Fuel Standard credits.
Components of Hydrogen Refuelling Stations
Hydrogen inlet: Refuelling stations are configured for optimum performance based on the hydrogen inlet pressure. The hydrogen can be produced on site most commonly via electrolysis, delivered to site and fuelled directly from a tube trailer or via on-site storage.
Compression: The hydrogen is then compressed to increase the pressure, and reduce the volume, to enable a greater amount of hydrogen to be stored in the system and an efficient flow of gas for dispensing.
Heat exchanger (process gas chilling): The compressed hydrogen is then passed through a heat exchanger to remove the excess heat from the gas that was generated during the compression process. Specially designed hydrogen-resistant valves and fittings are used to control the highly pressurised hydrogen. These components utilise specific materials that are resistant to hydrogen embrittlement to prevent any cracking.
Hydraulic power unit and controls: The process is powered, monitored and controlled via the electronic control panel in the non-hazardous zone.
Dispensing chiller system: The hydrogen is then cooled to subzero temperatures for fast and efficient filling to ensure the hydrogen can be dispensed safely and to comply with filling protocols.
Vent stacks: A safety feature to vent any escaped hydrogen safely. Hydrogen is lighter than air so dissipates quickly and safely, should an incident occur.
Storage: The high-pressure gas is then stored in the system until required for dispensing at the point of use. The storage is controlled by specially designed valves, fittings and electrical controls designed to regulate pressure and interact with the dispenser and vehicle as needed.
Dispenser: Designed to emulate traditional fuelling methods, the hydrogen is dispensed via a nozzle controlled by a smart valve which regulates the flow rate of the gas to fill the vehicle to the required pressure in accordance with the fuelling protocol.
After the liquefied or compressed hydrogen is trucked or piped (or the gas is produced via onsite water electrolysis), it enters a low-pressure storage cylinder or tank at a range from 290 psi (20 bar) up to 7,250 psi (500 bar).
In preparation for filling, compressors further reduce the hydrogen’s volume for medium- or high-pressure storage, a process that raises the pressure to as high as 13,050 psi (900 bar).
Due to compression and the Joule-Thomson effect, the gas heats up. To ensure that the hydrogen does not become too hot when dispensed, a cooling system brings the fuel’s temperature down to −40°F (−40°C) before it reaches the pump’s nozzle.
The tank is filled to 350 or 700 bar (5,075 or 10,150 psi), a process that takes about as long as filling a gasoline tank. Once in the vehicle’s tank, the hydrogen is at a comfortable 86°F (30°C).
How to Maintain Hydrogen Refuelling Stations
Proper training and knowledge
The first step in ensuring safety at hydrogen fueling stations is to provide comprehensive training to all personnel involved. This includes station operators, technicians, and maintenance staff. They should receive thorough instruction on the properties of hydrogen, safe handling procedures, emergency response protocols, and the proper operation of equipment. Regular training updates should be conducted to keep everyone informed about the latest safety practices.
Clear and visible safety signage is crucial for informing and instructing staff and customers about safety procedures and potential hazards. Place signage indicating no smoking, no open flames, and the location of emergency exits and safety equipment. Promote effective communication among staff members by promptly establishing clear protocols for reporting safety concerns or incidents.
Adequate ventilation and leak detection systems
Hydrogen is lighter than air, and in the event of a leak, it tends to rise and disperse quickly. However, proper ventilation is still crucial to maintain a safe environment at the fueling station. Install adequate ventilation systems that facilitate the quick dispersion of any hydrogen leaks. Additionally, implement reliable leak detection systems to promptly identify and mitigate any potential leaks, ensuring early intervention and preventing the buildup of hydrogen gas.
Regular maintenance and inspection of equipment are vital for ensuring safe operations at hydrogen fueling stations. This includes checking the integrity of storage tanks, pipes, valves, and dispensing equipment. Conduct routine inspections to identify any signs of wear, corrosion, or damage. Timely repairs and replacements should be carried out to prevent potential hazards.
Fire safety measures
Fire safety is paramount at hydrogen fueling stations. Essential fire safety measures you should implement include installing robust fire suppression systems, such as automatic sprinklers or specialized hydrogen fire suppression systems. These systems are designed to rapidly extinguish or control fires, minimizing their potential impact. Incorporate emergency shut-off systems that allow for the immediate shutdown of fueling operations in case of an emergency or the detection of a leak or fire.
Note：place fire extinguishers in easily accessible locations throughout the facility. These extinguishers should be specifically rated for use with flammable gasses, including hydrogen. Proper training should be provided on their usage.
The process of refuelling at a hydrogen station is not very different from that of a conventional petrol station, although there are some details that make the experience a little different. This is because hydrogen is supplied at high pressure and, as it is an extremely volatile gas, the connection between the vehicle's receptacle or connection point and the pump must be watertight.
The hydrogen is pumped into the vehicle's fuel tank, which powers the fuel cell that generates the electricity needed to drive the vehicle. The only waste product produced is water vapour, which is expelled through the exhaust pipe.
Unlike conventional filling stations, hydrogen is sold by the kilo, not by the litre, and the refuelling time for a conventional bus - which usually has a capacity of between 30 and 37.5 kilos - is no more than 12 minutes. And on the question of how much a hydrogen bus consumes, it is estimated at approximately 8 kilos per 100 kilometres, so the range of hydrogen vehicles currently on the market would be around 400 kilometres.
Hydrogen refueling stations can be deployed within either a depot-based environment or on land dedicated for a refueling hub, and it is likely that in a city-wide refueling network both scenarios will be required.
Stations can be designed to meet the specific needs of a fleet and so the footprint of a station can be tailored to fit into existing depot facilities. Of course, with limited space this can be challenging at times and so a dedicated piece of land for a refueling hub could make things easier, especially with future growth in mind.
A typical set of considerations for site selection would include the following:
● Available land for siting hydrogen infrastructure and mobile delivery assets, such as tube trailers.
● Locations available allowing existing traffic routes to pass the proposed station location.
● The ability to create safety distances between the hydrogen station and other areas of the site.
● The availability of utilities and possibilities to upgrade power provision (especially if onsite production is being considered).
● Site access and egress for hydrogen delivery vehicles, such as tube trailers
Third-party access potential, if within project scope.
Challenges and Solutions
Measurement technologies for a hydrogen economy must overcome some hurdles, most of which have to do with the element’s unique properties.
● Hydrogen permeation and embrittlement
As the smallest element, hydrogen ions can easily diffuse into most materials. Hydrogen permeation leads to embrittlement of the material. High temperatures and pressures accelerate permeation and embrittlement.
Solution: Ensure that the instrument’s wetted parts are made of hydrogen-compatible materials. A variety of alloys have an extremely tight cell arrangement that resist permeation. These include 316L (316 stainless steel with a low carbon content), 316Ti (titanium-stabilized version of 316), 2.4711 Elgiloy® (a “super alloy” of copper, chromium, nickel, and molybdenum), and other austenitic steels.
● Loss of containment
Leaks result in product loss and, in worst-case scenarios, explosions. Therefore, not only should the instrument’s material be hydrogen-compatible, but so should its seals, welds, and joints.
Solution: Choose instruments with a welded adaptation of wetted components. Polymeric sealing is fine for use with most other gases and liquids, but it is too porous for hydrogen applications.
● Signal offset
Hydrogen permeation can cause structural changes to the sensor element which results in signal drift which impacts the long-term reliability and accuracy of the instrument. As hydrogen fueling stations require signal stability for both safety and efficiency, only sensors made of hydrogen-resistant alloys will provide trouble-free operation and long service life.
Solution: For extra resistance to hydrogen permeation, the austenitic steel or special alloy can be coated with a metallic barrier. Gold is the most commonly requested material for plating, as this material is effective against permeation even at high temperatures.
Our Factory
Focusing on the R&D, manufacturing and sales of hydrogen producing and refueling equipment and key components for a closed-loop full ecological industrial chain featured by green power, hydrogen energy and end-use equipment, SANY Hydrogen Energy Co., Ltd. is the world’s leading provider of package solutions for hydrogen energy equipment, which is committed to providing global customers with GW-level ultra-large-scale package solutions on-grid/off-grid hydrogen production from wind and solar energy.
FAQ
