Hydrogen compressors account for 30% of the cost of hydrogen refueling stations

Hydrogen compressors are mainly divided into hydraulic piston hydrogen compressors and diaphragm hydrogen compressors. Piston compressors have a high gas output, but since they compress hydrogen through the back-and-forth movement of pistons, this process can contaminate the hydrogen, and leaks are likely to occur. Additionally, the problem of excessively high exhaust temperatures is difficult to resolve. Compared to piston compression, diaphragm compressors feature no contamination during compression, no leaks during the compression process, a high compression ratio, and high exhaust pressure. Therefore, the commonly used hydrogen compression equipment at present is diaphragm compressors. Diaphragm compressors can achieve an output pressure limit of over 100 MPa, and they offer excellent sealing performance; therefore, they are the ideal choice for hydrogen compression systems in hydrogen refueling stations. However, diaphragm hydrogen compressors require an extremely thin metal hydraulic drive diaphragm to completely separate the compressed gas from the liquid oil; their compression structure and cooling system are also more complex, making them far more technically challenging than conventional compressors. At present, the hydrogen compressors used in hydrogen refueling stations in our country still need to be purchased externally. Most of the existing compressor manufacturers in China are only capable of producing industrial hydrogen compressors for use in the petroleum and chemical industries, with output pressures below 30 MPa, which does not meet the technical requirements of hydrogen refueling stations. It is worth noting, however, that the proportion of domestically produced hydrogen compressors is gradually increasing; domestic equipment such as those manufactured by Zhongding Hengsheng and Tianhang has already been used in some hydrogen refueling stations in China. The main direction for the development of domestic equipment manufacturing is to accelerate the localization of hydrogen compressors, thereby reducing the construction costs of hydrogen refueling stations and promoting the growth of the hydrogen energy industry chain. In the future, with increased cooperation between domestic hydrogen stations and foreign companies that produce compressors, as well as an acceleration in the localization process, it is expected that the cost of compressors could be reduced by more than 50%.

At the product level, compressor suppliers are moving towards higher pressure and larger displacement solutions. Currently, 500-kilogram, 35MPa compressors are most commonly used in hydrogen refueling stations in China, but two trends are becoming increasingly evident: one is an increasing demand for 70MPa hydrogen refueling stations, and the other is a rise in the use of high-flow rate hydrogen refueling stations. For compressors, this means that high pressure and large displacement will be the trends in their development. ”An industry insider said as much. At the same hydrogen storage volume, higher pressure means a longer driving range and better fuel efficiency for the vehicle; data shows that 70MPa hydrogen provides a 67% greater driving range compared to 35MPa hydrogen. At the same time, as hydrogen-powered commercial vehicles become more widespread, the best way to enable hydrogen refueling stations to serve large fleets on limited construction land is to increase the displacement of the compressors. Under this trend, many companies are developing or have already launched high-pressure, high-displacement compressors. Among the diaphragm compressor suppliers, Zhongding Hengsheng has introduced compressors with a pressure of 90 MPa. Its project to produce 1,000 diaphragm compressors per year, including 100 such compressors for hydrogen use at 90 MPa per year, has passed the environmental impact assessment and is set to begin production soon. Fengdian Jinkaiwei has currently, in collaboration with the **Energy Group Beijing Institute of Low-Carbon Clean Energy, developed China’s first diaphragm compressor for hydrogen refueling stations with a large capacity of 90MPa that has passed hydrogen-related tests; it meets or even exceeds the requirements set for this project. East German Industry has also currently introduced 90MPa diaphragm compressor products. Among the suppliers of liquid-driven compressors, Hydracorp has designed high-displacement liquid-driven compressors tailored to the actual requirements of high-density commercial hydrogen refueling stations. These compressors feature a large discharge volume per unit, strong adaptability to inlet pressures, and high outlet pressures. The 90MPa liquid-driven piston compressor and intelligent integrated system for mobile hydrogen refueling stations, jointly developed by Sichuan Dachuan Compressor Company and Xi’an Jiaotong University, have been successfully developed recently. “Whether it is passenger vehicles or commercial vehicles, they are rapidly moving toward 70MPa levels. The hydrogen compressor manufacturers are introducing high-capacity products rated at 90MPa as a preparation for the era of higher pressures and larger capacities to come. ” said Guo Wei, CMO of Hydellison.

Application level: An increase in station compressors in specific scenarios. Hydrogen refueling stations are categorized into integrated hydrogen production and refueling stations, fixed-type hydrogen refueling stations, and skid-mounted hydrogen refueling stations. Based on a review of typical hydrogen station construction projects over the past six months, conducted by Gao Gong Hydrogen Energy, it has been observed that there has been a significant increase in the number of modular hydrogen stations as well as integrated hydrogen production and refueling stations. For example, CIMC AERIKO has recently developed and deployed the second-generation compact 35MPa hydrogen refueling unit in Foshan; this unit is designed for use in scenarios where hydrogen is required, such as port terminals, internal material handling operations, and fuel cell vehicle manufacturing facilities, providing hydrogen refueling for hydrogen-powered forklifts, test vehicles, and operational vehicles. Another example is that in April this year, China’s largest hydrogen fuel cell supply project in South China – the Sinopec Maoming Petrochemical Hydrogen Fuel Cell Supply Center – was successfully completed and has entered the production preparation phase. The project includes a hydrogen purification unit with a capacity of 3,000 standard cubic meters per hour, a hydrogenation hub (phase 1) with a capacity of 500 kilograms per day, and associated units. Once the project is put into operation, it will be able to produce 6,400 kilograms of high-purity hydrogen per day, supplying markets within a 200-kilometer radius. Given that the National Development and Reform Commission has explicitly called for the exploration of new models for hydrogen refueling stations that integrate hydrogen production, storage, and refueling within the medium- to long-term plan for the development of the hydrogen industry, and considering that provinces such as Guangdong, Shanghai’s Lingang area, and Chengdu in Sichuan have already introduced relevant policies and standards to accelerate the construction of demonstration hydrogen production and refueling stations, it is foreseeable that the use of hydrogen compressors for station use will continue to increase in specific applications in the future. Technical approach: Diaphragm type is favored / Liquid-driven type gaining attention. Among the three technical approaches used in hydrogen refueling stations – diaphragm compressors, liquid-driven compressors, and ion compressors – ion compressors are currently used less in China due to their high cost, and the products of companies other than Linde are not yet fully developed. However, these compressors offer advantages such as efficiency, no pollution, and the ability to handle high pressures and large flow rates, which makes them considered as the “next generation of products”. Among the commonly used diaphragm compressors and liquid-driven compressors, the diaphragm compressor is currently favored more due to its high level of technical maturity, good sealing performance, more stable quality control, and high efficiency. It is worth noting that, amid the trend toward larger displacement capacities, liquid-driven compressors are attracting increasing attention in the past two years due to their advantages in terms of displacement, as well as features such as modular design, relatively small size, easy maintenance, and long-lasting seals. Tomorrow, Fei *Chao, the manager of the H2 Energy Jinan hydrogen refueling station, told Gao Gong Hydrogen Power that the two technical approaches are suitable for different application scenarios and do not actually conflict with each other. Diaphragm compressors have significant advantages, and liquid-driven compressors also have suitable application scenarios; we are keeping an eye on liquid-driven compressors as well, and we wouldn’t rule out adopting this technology in appropriate situations.

Domesticization: The trend in hydrogen station operation is toward using domestic brands. As is well known, hydrogen compressors used in hydrogen stations are expensive, accounting for about 30% of the total cost of equipment required for building such stations; therefore, they represent an important factor in reducing the costs associated with station construction. In the past two years, the operation of fuel cell vehicles in China has entered the stage of commercial demonstration, resulting in a strong demand to reduce costs associated with the construction of hydrogen refueling stations. As a result, contractors responsible for such stations are placing increasingly strict requirements on cost control regarding hydrogen compressors. Under these circumstances, due to the high cost of imported brand compressors, domestic hydrogen station builders have begun to favor domestic brands. According to research by GGII, central state-owned enterprise clients operating hydrogen stations, due to their extremely high demands for safety and reliability, and influenced by historical and subjective factors, have traditionally preferred imported brands; as a result, imported compressors accounted for over 70% of the market share at one point. With the advancement of domestic hydrogen compressor technology and the higher overall cost-effectiveness of these compressors, the share of domestic brands has increased significantly. Currently, both types of compressors account for roughly 50% of the market each; Zhongding Hengsheng holds the largest share, followed by Hydrac. Companies such as Fengdian Jinkaiwei, Beijing Tiangao, Yu Hydrogen Equipment, and Compressors Inc. also have numerous application cases. “Imported compressor manufacturers have few employees in China, and they rely on third-party agencies for after-sales service, resulting in high labor costs. Under the current impact of the pandemic, the cost of overseas spare parts and their delivery speed may be affected. As the builders of hydrogen refueling stations, when purchasing equipment we no longer consider only the product’s performance; instead, we take into account the comprehensive service capabilities of the entire ‘supply chain’. ”A relevant official from a hydrogen station constructor in Guangzhou said. The hydrogen compressor used at the hydrogen refueling station by this company has been changed from an imported brand to a domestic brand from Shanghai.

On July 12, Cowclear Jingli (Suzhou) Hydrogen Energy Technology Co., Ltd. successfully held the shipment ceremony for the first batch of 4 electrolyzers with a capacity of 1,000 Nm3/h for Sinopec Xinxing Petroleum Company’s green hydrogen demonstration project in Kuche, Xinjiang. In this project, Coklear has adopted a modular hydrogen production system that utilizes 4 electrolyzers with a capacity of 1,000 Nm3/h each, along with one gas-liquid separation unit. This system features innovative, efficient, and integrated equipment technologies, providing strong support for China’s transition to clean energy; it holds milestone significance as a model for the development of the green hydrogen industry.

Since its commencement in March, the green hydrogen demonstration project in Kuqa, Xinjiang, has seen orderly and vigorous progress in its construction; to date, 880 million yuan has been invested, with the first production line set to begin hydrogen production on October 30. The Lihu Hydrogen Demonstration Project in Kuche, Xinjiang, is the first project in China to utilize photovoltaic power generation on a large scale for direct hydrogen production. With a total investment of nearly 3 billion yuan, it comprises five main components: photovoltaic power generation, power transmission and distribution, water electrolysis for hydrogen production, hydrogen storage, and hydrogen transportation. The project will involve the construction of a photovoltaic power plant with an installed capacity of 300 megawatts and an annual power generation output of 618 million kilowatt-hours, a hydrogen production facility capable of producing 20,000 tons of hydrogen per year, hydrogen storage tanks with a capacity of around 210,000 standard cubic meters, hydrogen transmission pipelines with a transmission capacity of 28,000 standard cubic meters per hour, as well as related power transmission and distribution facilities. Completion and operation are expected by June 2023. The green hydrogen produced by this project will be supplied to Sinopec’s Tahe Refining and Chemical Complex to replace hydrogen produced from existing natural gas-based fossil fuels. It is expected to reduce carbon dioxide emissions by 485,000 tons per year, contributing 130 million yuan to the local GDP on an annual basis and generating over 18 million yuan in taxes. It is reported that this project boasts four advantages: abundant resources, low carbon emissions, large-scale application, and technological breakthroughs. It is Sinopec’s first typical demonstration project that covers the entire process of green hydrogen production and utilization, including wind and solar power generation, transmission of green electricity, production of hydrogen from green electricity, hydrogen storage, hydrogen transportation, and the refining of green hydrogen. Once put into operation, the project will pave the way for new developments in green hydrogen-based refining, serving as a significant model for refining companies to utilize green hydrogen on a large scale in order to reduce carbon emissions. At the same time, all the key equipment and materials used in the project, such as photovoltaic modules, the electrolyzers that serve as the core component for hydrogen production through water electrolysis, hydrogen storage tanks, and hydrogen transmission pipelines, will be domestically produced. 2. **Zhejiang Taizhou Dachen Island Hydrogen Energy Comprehensive Utilization Demonstration Project**: This project was officially put into operation on July 8. It is the first comprehensive energy demonstration project for \"green hydrogen\" on an island in China. By making use of the abundant wind energy available on the island, the project generates hydrogen through water electrolysis using proton exchange membrane technology. A combined heat and power system consisting of hydrogen production, hydrogen storage, and fuel cells has been established, which helps to promote the use of clean energy on the island and optimize the flow of electricity in the grid. As a result, 100% of the clean energy produced on Dachen Island is utilized, with zero carbon emissions throughout the entire process. The project utilizes first-of-a-kind equipment such as integrated hydrogen production/power generation units. Once in operation, it is expected to consume 365,000 kWh of excess wind energy on the island each year, and produce 73,000 cubic meters of hydrogen. This hydrogen can be used to generate approximately 100,000 kWh of electricity, thereby reducing carbon dioxide emissions by 73 tons.