Hedley designed, fabricated, assembled and tested a 55kW hydraulic power unit for use in an ATEX hazardous area for hydrogen gas booster systems for use in the re-fuelling of hydrogen fuel cells, for a project located in Europe to power commercial and private hydrogen vehicles.

Purpose

To develop a hydraulic system to control the operation of a hydrogen pressure booster for use in a commercial automotive hydrogen fuel cell refuelling system. The ultimate aim being to develop a hydrogen fuel cell refuelling system that provides the ease of use and convenience of a conventional automotive filling station.

Problem

Advances in hydrogen fuel cell technology have led to the requirement for ever greater hydrogen pressures to be generated.  This requires the use of special purpose multi-stage pressure boosters.  In order to effectively charge the fuel cell, the hydrogen pressure must be precisely controlled, leading to the requirement for precise pressure booster control. 

Solution

A compact modular hydraulic system was developed, whereby the client was able to employ multiple units linked together to meet the needs of their standard range of hydrogen fuel cell refuelling systems.  As this is a relatively new technology a lot of additional development and testing was required including an ignition hazard assessment to ensure the HPU and its components were suitable for the ATEX hazardous area they were to be located in.

Outcome

Operational hydrogen fuel cell refuelling stations are now in use in the UK, Europe and Australia, operated by large automotive fleet users such as Deutsche Post, and The State Transit Authority of New South Wales.  

Hydrogen is a clean energy source, and this technology is taking a big step as a viable alternative to combustion engines.  Hydrogen is going to play a massive part in the future of sustainable motoring, and it was great to be a part of this project.

If you have a Hydraulic system you would like to make enquires about, please call us on 01924 259999.