Electrolysis Water Hydrogen Production Device

 

1. Enhanced with a suite of components including unloading, boosting, storage, and cooling modules, our fixed hydrogen refueling station offers seamless remote refueling capabilities alongside critical equipment status monitoring, cloud computing, and comprehensive big data analysis. Featuring rapid refueling speeds and a high refueling rate, it exemplifies efficiency and reliability.

2. Our skid-mounted hydrogen refueling station represents the pinnacle of integration, combining hydrogenation, cooling, metering, and digital control in a single, compact unit. Each station undergoes meticulous manufacturing, testing, and debugging processes within our factory, ensuring convenience, flexibility, and exceptional efficiency with a notably short construction cycle.

3. Whether opting for fixed or skid-mounted configurations, our hydrogen refueling stations are fully customizable to meet diverse customer requirements. They accommodate a variety of compressor options, including diaphragm or liquid-driven compressors, ensuring seamless integration tailored precisely to your needs.

 

 

1.Liquid-Driven Compressor

■ This compressor features a distinct separation between its oil and gas cylinders, employing oil-free lubrication for the piston to prevent any contamination of the compressed medium during operation. Utilizing a multi-seal design for the gas and oil chambers within specialized oil-gas isolation chambers ensures complete separation of oil and gas. Even in the event of damage to the sealing ring, this unique oil-gas isolation chamber structure guarantees that hydrogen remains uncontaminated by oil, thus preserving gas purity at the outlet. Dispensing with components such as crankshafts and connecting rods eliminates the need for a lubrication system in this compressor.

■ Hydraulic piston compressors exhibit low linear speed and switching frequency, ensuring prolonged service life for seals and valves compared to other reciprocating compressors. The gas cylinder piston is driven by a hydraulic system, minimizing vibrations and noise. The motor propels the high-pressure oil pump, which subsequently powers the compression cylinder under stable loading and operating conditions, thus extending the service life of both the compression cylinder and motor.

 

Powerful Displacement: Demonstrating exceptional performance, this compressor boasts a powerful displacement of up to 1000 Nm³/h at 12.5 MPa, providing robust support for the hydrogenation process.
High Pressure Output: Capable of achieving exhaust pressures of up to 45 MPa, it excels in high-pressure applications like hydrogenation, ensuring efficient and stable operation of production processes.
Wide Range Adaptability: With an inlet pressure range spanning from 2 MPa to 20 MPa, it accommodates various working conditions with remarkable flexibility.
Excellent Temperature Control: The maximum exhaust temperature does not exceed 120°C, and after cooling, the exhaust temperature drops to below 40°C, effectively maintaining equipment stability during prolonged operation.

Equipment Reliability

• Extended Sealing Life: Employing advanced sealing technology, this equipment ensures a sealing life of over 2000 hours, significantly reducing maintenance frequency and production downtime while enhancing overall reliability.
• Efficient Motor Drive: Equipped with a 110 kW main motor, it delivers robust driving force, ensuring efficient and stable operation while minimizing energy consumption costs.
• Low Noise Design: With noise levels kept below 80 dB(A), the equipment considers the heightened sensitivity of modern industrial environments to noise, thus ensuring a safe working environment for operators.

Name	Displacement	Exhaust pressure	Inlet pressure	Maximum exhaust temperature	Exhaust temperature (aftercooling)	Service life of seals	Main motor power	Noise
Parameter	≥1000Nm³/h@12.5MPa	45MPa	2~20MPa	≤120℃	≤40℃	≥2000h	110kW	≤80dB(A)

 

2.Compressor Skids

Modular Design: Our skids feature a module-based design, with separate modules allocated for the hydraulic system, compression system, heat exchange system, and pipeline system. This streamlined structure ensures ease of operation and maintenance.

Safety and Reliability: Within the skids, all electrical components are explosion-proof, complemented by a robust electrostatic grounding system. Full-lift safety valves are strategically integrated to prevent overpressure incidents. Furthermore, gas detectors are seamlessly incorporated into the skids, connecting to the Emergency Shutdown (ESD) system of the compressor. In the event of an emergency, this system automatically initiates shutdown procedures and cuts off the gas inlet.

Highly Automated Design: Embracing cutting-edge technology, our skids are equipped with a PLC fully automatic control system to manage compressor operations. The intuitive control panel provides real-time monitoring and diagnostic capabilities, complete with alarm notifications and automatic fault diagnosis. With features like one-click start and fault warning/diagnosis, operation is streamlined for maximum efficiency.

Comprehensive Water-Cooling System: Our skids are equipped with a full water-cooling system, facilitating more efficient heat exchange and ensuring lower exhaust and operating temperatures. This not only enhances performance but also prolongs the lifespan of critical components.

Regulatory Compliance: We prioritize safety and compliance, and thus, the entire equipment has obtained explosion-proof certification in accordance with the regulations of the region where it will be used. This certification underscores our commitment to delivering products that meet the highest standards of safety and reliability.

Indicator	Exhaust pressure	Default Dispensing Capacity	Operating Temperature
Parameter	45MPa	1000Kg/day	-25-55℃

 

3.Hydrogen Dispenser

Seamless Automation: Our hydrogen dispenser boasts fully automatic control, enabling effortless hydrogen refueling with just one click. Equipped with advanced leakage detection, alarm systems, and shutdown features, it prioritizes safety throughout the refueling process. Moreover, it automatically halts operations upon reaching the preset pressure levels of 35 MPa/70 MPa, ensuring safety remains paramount at all times.

Versatile Flow Range: With a wide flow range spanning from 0 to 5.0 kg/min, our hydrogen dispenser caters to diverse refueling demands, whether in small-scale laboratory settings or large-scale industrial applications.

Precision Measurement: Achieving a remarkable measurement fault of only ±1.5% and a repeatability of up to 0.5%, our dispenser guarantees accurate measurement and pricing during hydrogen refueling operations.

Safety and Explosion-Proof Design: Certified with an explosion-proof rating of Ex d e ib mb llC T4Gb, our equipment is engineered for utmost safety and stability. This designation ensures the dispenser operates reliably in hazardous environments, serving as a trusted safety assurance throughout the refueling process.

Name	Flow range	Measurement error	Measurement repeatability	Operating pressure	Explosion-proof grade
Parameter	0~5.0Kg/min	±1.5%	0.50%	35MPa/70 MPa	ExdemibllCT4Gb

 

4.Sequence Control Panel

Modular Design: Featuring a module-based pipeline structure, our sequence control panel simplifies maintenance and repair tasks for staff, ensuring operational efficiency and ease of maintenance.

Efficient Program Control: Equipped with an efficient program control design, our panel enables automatic refueling and storage processes, facilitating simultaneous refueling of multiple hydrogen-fueled vehicles through the utilization of multiple nozzles.

Safety and Reliability: Hydrogen pipes are securely connected using Autoclave fittings (C&T fittings) or NPT fittings, ensuring robust and reliable connections. Additionally, all electrical components meet stringent explosion-proof requirements, guaranteeing the safety of operations.

Adaptability to Various Conditions: Engineered to perform reliably in diverse environmental conditions, our sequence control panel boasts an operating temperature range spanning from -40°C to 50°C. This wide temperature tolerance ensures seamless operation across a spectrum of operating conditions, enhancing its adaptability and versatility.

Name	Applicable medium	Operating pressure	Design pressure	Environment temperature	Rating
Parameter	H2	45MPa	50MPa	-40°C~50°C	III

 

5. Discharging column

Sophisticated pipeline design: The entire pipeline is arranged following a clear flow process made up of primary and secondary sections. The primary section (for hydrogen) and secondary section (for nitrogen purging used in the replacement reactions) are easy to identify, which can effectively improve the accuracy and safety of operations and reduce misoperation.

Safe and reliable design: The gas for instruments and purging are isolated. Full-lift safety valves are used. The pipeline is designed with an automatic leak detection feature.

Precise measurement repeatability: The measurement repeatability of the discharging column is 0.5%. Precise measurement control ensures accurate and stable discharging.

High filtration precision: High-efficiency filters of 5μm can remove other impurities from hydrogen and improve the purity of hydrogen.

Name	Applicable medium	Operating pressure	Design pressure	Measurement repeatability	Filtration accuracy
Parameter	H2	0~20MPa	25MPa	0.50%	5μm

 

The hydrogen dispenser is to refill hydrogen, which consists of pressure sensors, temperature sensors, metering units, intake priority control units, safety units, etc. When a FCEV needs to be refueled with hydrogen, the hydrogen dispenser is first supplied with gas from the tube trailer in a hydrogen refueling station with 4-level storage of gas. When the hydrogen pressure in the tube trailer reaches equilibrium with that of the on-board hydrogen storage cylinder, the gas will be supplied by the low-pressure hydrogen storage cylinder. Like this, the gas is supplied from the medium-pressure and high-pressure hydrogen storage cylinders, respectively. When the pressure of the high-pressure hydrogen storage cylinder fails to fill the vehicle-mounted hydrogen storage cylinders to the set pressure level, the compressor starts with refueling. After refueling, the compressor replenishes hydrogen to the high-pressure, medium-pressure and low-pressure hydrogen storage cylinder in sequence for next refueling service. This sequential refueling approach method results in less wear to the compressor.

 

 

 

 

The workshop spans an impressive 216 meters in length and 72 meters in width, encompassing three distinct zones totaling approximately 15,000 square meters. Zone A serves as a dedicated space for our machine processing line, slated for deployment in 2024. Meanwhile, Zone B houses a state-of-the-art hydrogen refueling station assembly line boasting an annual capacity of 20 sets. Finally, Zone C is home to a cutting-edge hydrogen-producing equipment assembly line, capable of producing 2GW alkaline water electrolyzers annually.

Commencing construction in January 2023, the entire production line was swiftly completed and operational by March 2023. This rapid turnaround not only underscores SANY's agility but also highlights our prowess in equipment manufacturing.

①Welding Robot Work Station

Available in September 2023, and independently developed by the SANY Robotics R&D team, the welding robot work station consists of a truss unstacking system, a robotic handling system, a laser welding system, a visual recognition system, and a bipolar plate flipping system. In every 5 minutes, a bipolar plate is welded with the electrode mesh, and a circular pressure plate then rolls off the assembly line. The entire process from feeding, flipping, blanking to welding is fully automated by robotic equipment. The manufacturing process is not only efficient, but also standardized, which can avoid damages to the bipolar plate coating during handling and rotation, greatly improving product quality.

 

 

②Spot Welding of Round Tablets

Spot welding is used for the fixation of round tablets. Compared with the traditional gluing technology, the spot welding is superior in the following aspects. First, it avoids the detachment. It has been verified by experiments that the adhesive of the round tablet would be melted and peeled off by the alkali solution during the operation of the electrolyzer, which then remains in the pressure pipe, posing a great impact on the performance. Second, it enables the firm fixation, reducing the risk of misalignment and falling during the assembly process. Third, it improves efficiency. The traditional gluing technology requires 15 minutes for drying, which affects the overall efficiency of assembly. No waiting time is required for the spot welding technology.

 

③PPS Separator CNC Cutter

Put into use in August 2022, this A6-2525 automated PPS separator cutter has an effective operation area of 2500 mm×2500 mm. Equipped with infrared positioning and high precision linear guide rails and pinions, it can achieve an cutting accuracy of ± 0.5 mm. It is also equipped with a 12.5 KW fan that ensures the flattening of the separator through vacuum adsorption to provide consistent cutting. The automatic feeding device made up of the feeding bearing, cylinder and belt ensures the flattened separator conveys to the cutting station automatically, enabling unmanned feeding and cutting.

 

 

④Electrode Laser Welding Process

The automatic electrode laser welding machine was put into use in December 2022. With the dominant PLC controlling, it is compatible for 1000 to 2500 mm electrode welding. It adopts a powerful 1500W or above continuous laser welding unit, a flat platform with movable fixtures for multi-point clamping of the bipolar plate to remove the Z-axis unevenness, and the rotary table shifts less than 0.5 mm on the Z axis with no focal length deviation of the laser welding. The pressing block adopts an arc-like design to fully press the parts. Through trial programming, it can finish the welding of an entire bipolar plate all at once by automatically skipping the hollow part in the middle. Every time the welding is completed, the turntable automatically returns to the nearest starting point of welding. Laser welding with filler wire achieves the accuracy of 0.5 mm. The welding seam is even, delicate and smooth, and the surface is white and bright.

 

 

⑤Hydrogen Separation and Purification System Assembly Area

SANY's hydrogen separation and purification system is powered by our self-developed intelligent pipeline design platform, which ensures an annual production capacity of more than 160 sets. The assembly area consists of a final assembly unit and a pipeline prefabrication unit. The final assembly unit can efficiently assemble 5 sets of separation and purification systems at the same time, and the pipeline prefabrication unit involves the blanking, bending, welding and prefabrication of pipelines. The production line has 5 separation system assembly stations and 5 purification system assembly stations, independent pipeline welding stations, pipeline slope cutting and bending stations, and air tightness test stations to achieve the unified process from pipeline prefabrication, overall assembly to end-of-line testing, which is able to deliver one set of separation and purification system in 10 days.

Pipe Bender: Two sets of CNC benders are used. Currently, they can only bend 0-40 mm pipes with the accuracy of 0.05 mm. We are developing the bending technique for pipes in a larger diameter, which is planned to be put into use in 2024.

Automatic Pipeline Cutting and Beveling Line: The line consists of a pipeline feeding system, a hydraulic rotation system, a length measurement system, a cutting and beveling machine, a laser coding system, a discharging system, a material retrieval system, etc., which realizes the entirely automatic process from raw materials onto the line to finished pipelines off the line. Its processing accuracy is less than 0.5 mm. The efficiency is increased by more than 3 times, and it can handle up to Φ350mm pipes.

Pipe Bender: Two sets of CNC benders are used. Currently, they can only bend 0-40 mm pipes with the accuracy of 0.05 mm.

Automatic Pipe Welding Machine: It can automatically weld the straight pipes and straight pipes, straight pipes and bent pipes, straight pipes and tees in thickness of 2-10 mm and diameters of 0-400 mm. It uses the argon arc welding technique, which is more than three times faster than manual welding. It also greatly improves the welding quality. Currently, the first-pass rate of flaw detection exceeds 99%. The welds are processed using a weld cleaning machine imported from Germany, which allows better antioxidant capacity than that of the traditional pickling and passivation treatment. The cleaning is environmentally friendly with no waste liquid.

 

 

⑥Electrolyzer Assembly Station

The electrolyzer assembly station is made for the final assembly of electrolyzers, consisting of 5 sets in total. Each set uses a flexible design to meet the production needs of up to 3,000 Nm³/h. Each assembly station is composed of a hydraulic hoisting platform and a screw drive lifter. The hydraulic hoisting platform realizes the assembly requirements at the height of 0 to 7.5 meters, and the screw drive lifter significantly simplifies the total assembly process, which also saves a great amount of plant vertical space, eliminating the plant height limitation issue. The electrolyzer assembly process uses positioning pins and sophisticated 5-line laser leveling technique to ensure a precise stack assembly outcome (the vertical deviation of the electrolyzer to be within 5 mm). The 18-axis hydraulic tensioner completely eliminates inefficient actions such as frequent disassembly and assembly of tensile screws during the tightening process, reduces the workload on employees, and doubles the efficiency.

Electrolyzer Assembly Process:

Vertical Stacking Control Process for Large Electrolyzers: It enables the control over the stacking of bipolar plates in vertical and circumferential directions through standardized measures such as five-line levels and positioning pins. Currently, the vertical deviation of 1000 Nm³/h electrolyzers can be controlled within 5mm.

Tightening Process for Electrolyzers: The 18-axis tightening process is adopted. All parameters of the three major techniques including cold tightening, heat tightening, and final tightening are under control. The distance between hemispherical poles is evenly controlled at 0.3mm, and the overall tightening deviation is less than 3 mm.

 

 

⑦ Gasket Cutter

The gasket cutter adopts an aerospace-grade aluminum honeycomb adsorption panel, by utilizing profiling tools, negative pressure vacuum and infrared calibration to achieve fixing and positioning of gaskets. During gasket processing, a combination of vibrating cutter and milling cutter is used for hole, groove and step surface processing, and the final product has an overall accuracy of 0.5 mm.

 

 

⑧ Pipeline Prefabrication Area

The pipeline prefabrication area mainly consists of pipe cutting, pipe bending, pipe welding, and pipe pre-assembly. Pipe cutting involves the cutting and beveling of stainless steel pipes. The main equipment includes band saws, beveling machines, and semi-automatic cutting and beveling integrated machines, meeting the production requirements for pipe diameters ranging from 0 to 400 mm. Pipe bending is carried out using two sets of CNC bending machines to meet the bending needs of pipes ranging from 0 to 40 mm, with a bending accuracy of up to 0.05 mm. Pipe welding employs a fully automatic pipe welding machine to fulfill automatic welding requirements for straight-to-straight pipes, straight-to-bent pipes, and straight pipes to tees within the thickness range from 2 to 10 mm and diameter range from 0 to 400 mm. The use of argon arc welding technology achieves a welding speed of over three times that of manual welding. Weld seams are treated using a German-imported weld seam cleaning machine, which provides oxidation resistance surpassing traditional acid pickling and passivation processes, ensuring that the cleaning process generates no waste liquid, thus being environmentally friendly. For pipe pre-assembly, specialized combination fixtures with a positioning accuracy of 0.5 mm are utilized, meeting the assembly and positioning requirements of pipe assemblies. This facilitates offline batch pre-assembly of pipe assemblies and fulfills the requirements for online assembly, serving as a crucial step in achieving large-scale production for the separation and purification system.

 

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