Hydrogen compressors have broad applications in pressurizing, storing, transporting, and utilizing hydrogen. Choosing a high-performance and dependable hydrogen compressor is crucial for industrial and commercial purposes. Compressed hydrogen demands differ depending on the usage, and various hydrogen compressor types are designed to meet different standards and requirements at varying pressure or flow levels. This article will explore the hydrogen compressor types commonly used in the chemical and energy sectors.
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Hydrogen is widely used in industry, with over half of production going towards ammonia, methanol, and refining processes. We can obtain it from fossil fuels or biomass or generate it using water electrolysis. Hydrogen is gaining traction in transportation and energy-related sectors as a potential alternative energy source. Although, these applications currently account for less than 10% of global hydrogen consumption.
Hydrogen has various industrial applications across diverse sectors, including:
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Hydrogen, with its low density and large volume at room temperature, poses challenges for storage and transportation. Hydrogen compressors are employed to safely and efficiently compress it for storage and use.
In chemical production processes where hydrogen is utilized as the feed gas, piston compressors facilitate the chemical reaction by compressing hydrogen to high pressure. For instance, in the ammonia industry, hydrogen-nitrogen mixture is compressed through 6-7 stages to reach a final exhaust pressure of 31.4MPa, while in coal chemical synthesis gas to methanol process, the inlet pressure of hydrogen and carbon dioxide mixture is 2.5MPa, and the final exhaust pressure can reach 5-10MPa or 35MPa.
Hydrogen-powered vehicles are gaining popularity, and hydrogen compressors play a critical role in refueling. They compress the fuel for delivery to refueling stations or during the unloading and filling phases. The most economical method is to compress hydrogen at very high pressures, typically between 350 and 900 bar, before storage and use. For instance, transport fuel cell systems typically store hydrogen at 70 MPa or higher.
Compressors are machines designed to increase the pressure of air and other gases. The compression of air can be achieved through two primary mechanisms. The first is a volumetric compressor, which physically reduces the volume of the container holding the air, making the gas more compressed and dense. The second mechanism is a centrifugal compressor, which increases the velocity of the gas, leading to an increase in pressure and a decrease in volume. Hydrogen compressors are specifically designed for compressing hydrogen gas.
Given the unique properties of hydrogen and the expanding range of hydrogen applications, it is critical to use compressors that can safely handle and discharge the gas for optimal efficiency.
When discussing compressors, the compression ratio is defined as the ratio between the outlet and inlet pressure. For instance, if a compressor takes in gas at a pressure of 20 bar and raises it to 200 bar at the outlet, the compression ratio would be 10 (calculated as 200 bar divided by 20 bar).
In large-scale chemical processes that involve hydrogenation, there are two main types of compressors: those that transfer pressurized fresh hydrogen to the reaction system to replenish the hydrogen consumed by the reaction, known as supplemental or fresh hydrogen compressors. Due to the relatively significant pressure difference between the inlet and outlet of these compressors and the relatively low flow rate, reciprocating compressors are typically used.
Reciprocating compressors are volumetric compressors that use a linear drive motor to move a piston or diaphragm back and forth, thereby compressing hydrogen by reducing the volume occupied by the gas. These compressors are insensitive to the molecular weight of the gas. They can achieve high compression ratios through multiple compression stages, making them suitable for reducing fresh hydrogen.
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Another type of compressor used in hydrogenation plants is the circulating hydrogen compressor. Its role is to compress and cool the circulating gas and send it back to the reaction system to maintain the reactor’s hydrogen partial pressure. Due to the significant gas flow rate and slight pressure difference, centrifugal compressors are typically used for this purpose.
Centrifugal compressors rotate a turbine at high speed, throwing the gas into the diffuser behind the working wheel. The gas gains pressure from centrifugal action and can leave the working wheel at high speed. The diffuser reduces the gas speed and transforms kinetic energy into static pressure energy, increasing the pressure.
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The hydrogen compressor is a crucial component pressuring hydrogen into the storage system. Due to the low density of hydrogen and the potential hazards of flammability and explosion, a hydrogen compressor’s most essential performance indicators are its output pressure and gas containment capabilities. Hydraulic piston compressors, diaphragm compressors, and ionic liquid compressors are commonly used in hydrogen refueling stations. Diaphragm and hydraulic piston compressors are primarily used in hydrogen refueling stations where the hydrogen storage pressure does not exceed 45MPa. In contrast, ionic liquid compressors are used in hydrogen refueling stations where the hydrogen storage pressure reaches 90MPa.
The diaphragm compressor is a device that compresses gas by reciprocating the motion of a piston driven by an electric motor. Unlike piston compressors, the diaphragm compressor adds liquid oil and a diaphragm between the piston and the gas. The diaphragm is fixed between the dome-shaped cover and the body, and when it deforms up and down, the volume of the diaphragm cavity changes, completing the compression and exhaust of gas. The diaphragm compressor has a hydraulic drive diaphragm, which provides good sealing, efficiency, and heat dissipation.
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Hydraulically driven piston compressors are positive displacement compressors that work on the same principle as ordinary piston compressors for compression components. However, instead of using a crank linkage mechanism, the piston is driven by a hydraulic system.
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Ionic liquids are salt molecules with unique chemical and physical properties that make them useful in various applications, such as aerospace, automation, electronics, and energy. In an ionic liquid compressor, a hydraulic piston drives an ionic fluid into a cylinder to compress the gas. A high-pressure liquid pump circulates the ionic fluid, and it has excellent lubrication and cooling properties while being virtually incompressible and not dissolving or contaminating hydrogen.
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Hydrogen compressors can be categorized into horizontal, vertical, and angle compressors based on the relative position of the base ground plane and cylinder centerline. Vertical and horizontal compressors with cylinders on the crankshaft side are suitable for low air volume conditions. The symmetrical balance compressor is a commonly used medium to sizeable reciprocating compressor in the horizontal compressor category. This compressor has multiple cylinders distributed symmetrically on both sides of the crankshaft at a 180° angle to the cylinder centerline. The opposed compressor is suitable for compressing high-pressure gases, while the angle compressor is suitable for small to medium-sized compressors. The angle compressor can be further divided into different types, such as W-type (60° clamping angle), L-type (90° clamping angle), and fan-type (40° clamping angle), depending on the angle of clamping.
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