Hydrogen Applications

Hydrogen Refueling Stations (HRSs)

A global leader in providing comprehensive solutions for the design, installation, and operation of HRSs of varying scales globally.

Have participated in the constructions of over 105 HRSs globally with refueling capacity ranging from 80 to 6,400 kg H₂ per day as of December 31, 2024.

Construciton of the world's largest HRS with refueling capacity of 6,400 kg H₂ per day.

Rapidly expanding HRS business in global markets.

The electrical consumption during refueling is 1.2kWh/kg.

We provide integrated solutions including design, installation, operation,
and maintenance of proprietary product offerings to customers

Hydrogen Refueling Technology

Hydrogen refueling stations (HRSs) form essential infrastructure for the operation of hydrogen fuel cell vehicles. The performance of hydrogen refueling equipment plays a pivotal role in ensuring the safety and efficiency of the refueling process. We have designed and developed a set of specialized hydrogen refueling equipment with high level of reliability and performance, benchmark safety, and modular design, including hydrogen compressor, dispenser, supply cabinet, cascade control cabinet, nitrogen cabinet, and filling cabinet. All our proprietary hydrogen refueling equipment incorporates a unified operating system, ensuring seamless compatibility with one another and enhancing the safety, stability, and efficiency of the refueling process, along with notable energy consumption reduction compared to the industry averages. Leveraging our advanced hydrogen refueling technologies, our solutions can efficiently serve the demands of HRSs with a wide range of service capacity from 80 to 6,400 kg of hydrogen per day.

Key Equipment of HRS

Skid-Mounted HRS

Compressor

Hydrogen Dispenser

Supply Cabinet

Cascade Control Cabinet

Filling Cabinet

Skid-mounted HRS

The skid-mounted compressor and hydrogen dispenser is an integrated whole equipment to achieve hydrogen compressing and refueling for temporary or mobile hydrogen refueling applications. We can provide the equipment of various specifications such as 70MPa and 35MPa hydrogen refueling capacities. Besides, we can also customize the flow rate, pressure and refueling rate of the equipment for application scenarios of laboratory, forklift, drone, etc.

Product Strengths

Modular and integrated design

Compressor, hydrogen dispenser, and complementary facilities are all modular designed with all joints set to facilitate installation.

Compressors, hydrogenators, and ancillary facilities are modular in design, with pipe ports and connections centrally located for easy installation.

Integrated motor interface and operating screen.

Small footprint and quick installation

Integrated skid-mounted structure, with reasonable internal layout.

The equipment can be easily transported, quickly installed and commissioned.

Multiple security mechanisms

Thorough safety interlock system and independent self-leakage detection technology, automatic alarm and shutdown for abnormal conditions.

Integrated with hydrogen detector, flame detector, natural ventilation and forced ventilation, creating system interlock control.

Long service life design & reliable quality

The equipment is qualified with explosion-proof certificate, and qualified report from third-party inspection and testing center.

Meets the 35MPa and 70MPa refueling requirements.

Convenient operation and maintenance

The integrated control mechanism can achieve button- start/stop.

Digital screen with working and alarm status display.

Automatic stop of pressurization when refueling is completed.

Reserved operation and maintenance space, facilitating operation and maintenance.

Technical Parameters (standard configuration)

Equipment

70MPa skid-mounted hydrogen refueling station

35MPa skid-mounted hydrogen refueling station

mobile skid-mounted hydrogen refueling station

Inlet pressure

5~30MPa

1~20MPa

Rated discharge pressure

70MPa/90MPa

35MPa/45MPa

Rated discharge flow

500kg/12h

System Configuration

90MPa hydraulic compressor + 70MPa hydrogen dispenser

45MPa diaphragm compressor + 35MPa hydrogen dispenser

22MPa skid-mounted compressor and chiller station + 45MPa skid-mounted compressor, chiller and hydrogen dispenser station

Application scenarios

Hydrogen refueling for 70MPa commercial vehicle , suitable for leasing.

Hydrogen refueling for 35MPa heavy-ducy truck , suitable for leasing.

Mobile hydrogen refueling, dual skids can be operated independently

Dimension LxWxH （m）

10x3.1x2.7

10.5x3x2.8

7x3x2.7+5x3x2.7

Compressor

The hydrogen compressor is the key equipment critical to the hydrogen refueling station for hydrogen pressurization. We provide hydrogen compressors of various specifications, involving diaphragm and liquid-driven compressors.

Our diaphragm hydrogen compressor boasts enhanced flow rate, high pressure ratio, and impressive reliability and durability. The compressor features a modular design and assembly, increasing production efficiency, and reducing production errors and costs. Its high flow rate and pressure ratio enable quick and efficient hydrogen filling for vehicles. Within the compressor, we have integrated an automated control system and a predictive maintenance system, both developed in-house using artificial neural networks and machine learning algorithms. These advanced systems enhance equipment efficiency, bolster operational reliability, and reduce energy consumption. Notably, the lifespan of the compressor’s diaphragm reaches 4,000 hours in operation, surpassing the industry’s average range of 2,000-3,000 hours.

Product Strengths

Cutting-edge remote monitoring platform

Providing compressor operation analysis reports that encompass comprehensive data statistics, operational status assessments, trend analyses, and maintenance recommendations, ensuring stability and efficiency operation.

High efficiency and low energy consumption

Compressor head built-in cooling system technology reduces energy consumption for cooling.

Special design increases hydrogen discharging flowrate by 10% comparing to domestic compressors with equivalent specifications.

Multiple energy-saving mechanisms such as frequency conversion regulation.

Long service life design & reliable quality

Unique chamber design, improving the service life of the compressor diaphragm.

Unique vibration damping design, ≤2mm/s.

Design of automatic standby cycle bypass, integrated with time switch function, can reduce frequent start-stop.

Convenient operation and maintenance

Four standardized operation modes: operation mode, purge and gas replace mode, self-test mode and maintenance mode, can achieve one press operation switching.

Reserved reasonable operation and maintenance space and configured with overhauling equipment to facilitate maintenance.

User friendly mechanical engineering design of pipe.

Multiple security mechanisms

Three-layer diaphragm, double-layer sealing and diaphragm leakage monitoring system, ensuring zero leakage and preventing hydrogen pollution during compression.

Thorough safety interlock system and independent self-leakage detection technology, with whole monitoring of the operation process.

Multiple sensors for full-time situational awareness during

Technical Parameters (standard configuration)

Compressor Capacity

500kg/12h

1000kg/12h

Inlet pressure

5~20MPa

Outlet pressure

45MPa

Rated discharge flow

530Nm³/h@12.5MPa

1150Nm³/h@12.5MPa

Max. discharge flow

920Nm³/h@20MPa

1990Nm³/h@20MPa

Drive power

55kW

110kW

Shaft power

41.8kW

87.3kW

Type

diaphragm compressor

Stage of compression

1 stage

Cooling demand

refrigerating capacity 35kW，water cooling

refrigerating capacity 75kW，water cooling

Transmission type

Belt / Coupling

Dimension, LxWxH（mm）

4800×2400×2300

5500×2500×2500

Hydrogen dispenser

Our high-performance dispenser exhibits significant advancements. It can meet the hydrogen refueling demands of both 35MPa and 70MPa, accommodating a wide range of hydrogen-powered vehicles. To ensure safe refueling operations under all conditions, we have established a handshake protocol that connects our dispenser with the security system of the HRS. The dispenser is also equipped with a hydrogen-precooling system that employs our proprietary algorithms to control the level of precooling based on environment temperature, thereby enhancing the refueling speed while conserving energy. Furthermore, the dispenser supports flexible payment methods, including fingerprint and facial recognition, and online payment, among others, to cater to diverse preference of customers. Our dispenser is also IP55 certified in recognition of the safety of the machine and its control system.

Product Strengths

Innovative design

The proprietary algorithms can control the cold supply of the chillers according to ambient temperature, to achive energy saving, and increase hydrogen refueling speed and SOC;

Integrated with manual and automatic venting, and restriction of flow at the outlets

Multiple modes of payment are available, including fingerprint payment, face recognition payment, online payment, etc.

Multiple application scenarios

Adapt to 35 MPa and 70 MPa refueling of hydrogen fuel cell vehicles.

Equipped with hidden pre-cooling heat exchanger, it can be installed in pipe trench or underground to save land occupation.

Provide customized design service to meet the needs of automobiles, trains, drones and other special hydrogen scenarios.

Multiple security mechanisms

Combining DFMEA and PFMEA design methods, ensuring the intrinsic safety of the equipment.

Independent self-leakage detection technology, integrated through a handshake mechanism with the whole station safety system to ensure refueling under safe conditions.

Multiple environmental sensing, such as hydrogen detectors and ambient temperature sensors, ensuring that the safety working environment.

Modularized and integrated design

Rational and compact design, decreasing land occupation.

The modular and symmetrical design with standard internal pipe and valve fittings can ensure quick product delivery.

Convenient and complete functions

One-button refueling with multiple hydrogen refueling modes.

Multiple functions, such as shift totalization, power failure protection, delayed display and redisplay.

Equipped with sampling and nitrogen purge replacement interface, nitrogen purge gun can be configured .

Technical Parameters (standard configuration)

Refueling pressure

35MPa

70MPa

35+70MPa

Flowrate range

≤7.2kg/min

Indication error

≤±1.5%

Measuring accuracy

≤±0.5%

Measurement repeatability

≤0.5%

Nozzle type

TK25/TK16

TK17

TK25/TK16+TK17

Nozzle qty.

2 or 1

Explosion-proof level

ExdⅡCT4

IP level

IP55

Supply cabinet

The supply cabinet unloads low-pressure hydrogen from cylinder trailer to compressor. With functions of blowing replacement and emergency shut-off, the equipment is reinforced with double valve assembly for nitrogen blowing replacement pipeline to prevent hydrogen penetration, and a 0.2m guide hose to facilitate the free operation of pull-off valves.

Product Strengths

Modular and integrated design

The modular and symmetrical design with standard internal pipe and valve fittings can ensure quick product delivery.

Most pipe and valve fittings are internally integrated to greatly prolong service life.

Multiple application scenarios

Adapt to 20 MPa and 30 MPa hydrogen tube-tailer.

Integrated single-channel or double-channel hydrogen unloading in one unit to save land occupation.

Expandable functions, such as built-in nitrogen cylinder, built-in control system, built-in decompression system and automatic blowing replacement function.

Accurate metering and reliable operation

High-precision pressure sensor, ensuring the accuracy of pressure detection.

High-precision mass flow meter, setting with temperature and pressure compensation.

The inlet is equipped with large flux filter of 5μm precision to prevent impurities from entering.

Setting with outlet temperature sensor for temperature real-time monitoring.

Convenient operation and maintenance

The internal layout pipe and valve fittings is optimized to facilitate observation, operation and maintenance.

The openable cabinet door is convenient for servicing or maintenance.

Multiple security mechanisms

Independent self-leakage detection technology, automatically monitoring hydrogen leakage.

The unloading hose is equipped with a breakaway valve, a protective sleeve and an anti-dumping device; Unique 0.2m guide hose ensuring the breakaway valve can work smoothly.

Equipped with built-in hydrogen detector and automatic breakaway valve, interlocking with the station safety system to realize automatic shut-off or remote urgent stop.

Technical Parameters (standard configuration)

Process gas

Hydrogen (99.99% purity)

Design pressure

25MPa

33MPa

Working pressure

20MPa

30MPa

Design temp.

-20-60℃

Length of guide hose

0.2m

Length of discharge hose

≥5m

Interface spec.

CGA1350 (connected to hydrogen cylinder trailer) or customized

Interface type

Double ferrule/ C&T

Interface qty.

Single or dual interface

Purge and replace function

DBB design, avoiding hydrogen backflow into the nitrogen pipeline.

Filtration accuracy

5μm (inlet filter)

Explosion-proof level

≥ExdⅡCT4 GB

Dimension, LxWxH（mm）

~1690×766×1780

Cascade control cabinet

Combined with the self-developed control system of the overall station, the cascade control cabinet can automatically regulate the storage and withdrawal of hydrogen in the station to greatly improve the utilization rate of the cylinders.

Product Strengths

Multiple application scenarios

Suitable for both 45MPa and 90MPa hydrogen refueling station.

Control the sequence of hydrogen storage and refueling for multipe pressure hydrogen storage cylinder sets such as 20MPa, 45MPa and 90MPa and improve the cylinder utilization rate.

Providing standard single, double & triple system cascade control cabinets, and customized multi-input & multi-output cascade control cabinets are available.

Modular and integrated design

Rational and compact design, decreasing land occupation.

Modular and standarized design, common internal pipe valve parts, quick delivery.

Symmetrical design, from low to high pressure pipe interfaces corresponding to the cylinder sets, ensuring smoother pie connection.

Pipe and valve fittings are internally integrated.

Convenient operation and maintenance

Optimized internal layout pipe and valve layout, facilitating observation, operation and maintenance.

Openable cabinet door, convenient for maintenance.

Multiple security mechanisms

Combining DFMEA and PFMEA methods, ensuring the intrinsic safety of the equipment.

Equipped with intelligent station control system, can automatically cut off hydrogen gas in emergency situations.

Independent self-leakage detection technology, automatically monitoring hydrogen leakage.

Accurate metering and reliable operation

Configure high-precision pressure sensors for hydrogen storage cylinder set, realizing precise linkage with automatic valves in the cabinet.

Equipped with temperature sensors, automatically temperature monitoring.

Manual venting valve is equipped on each pipe.

Technical Parameters (standard parameters)

Charging pressure

20MPa

45MPa

90MPa

Design pressure

25MPa

49.5MPa

99MPa

Tube material

316/316L stainless steel

Explosion-proof level

≥ExdembibⅡCT4Gb

System design

No grading

There grading: high, medium and low

High and medium grading or high only

Inlet

Single inlet connected to 20MPa compressor

Single inlet connected to 45MPa compressor

Single inlet connected to 90MPa compressor

Outlet 1

Single outlet connected to 20MPa hydrogen storage cylinder set

Three outlets connected to high, medium, and low pressure of 45MPa hydrogen storage cylinder sets

Single/dual outlets connected to the high or medium pressure of 90MPa hydrogen storage cylinder set

Outlet 2

Single outlet connected to 45MPa compressor

Single/dual/triple outlets connected to 35MPa hydrogen dispenser

Single outlet connected to 70MPa hydrogen dispenser

Explosion-proof level

ExdⅡCT4

Filling Cabinet

The filling cabinet supplies hydrogen to cylinder trailer or hydrogen cylinder assembly. With functions of blowing replacement, metering and emergency shut-off, the equipment has different specifications such as 20MPa and 30MPa filling capacities, and single or dual system designs to cover various application demands. In addition, the equipment is reinforced with a guide hose to facilitate the free operation of pull-off valves, and can be customized with a high-accuracy mass flow meter, automatic blowing replacement and sample interface, etc.

Product Strengths

Convenient operation and maintennace

Optimized internal layout pipe and valve layout, facilitating observation, operation and maintenance.

Equipped with openable cabinet door, convenient for servicing or maintenance.

Multiple application scenarios

Suitable for 20MPa/30MPa filling capacity.

Single/double/triple channel filling available in a single unit, space saving.

Customized filling cabinet for large flow rates are available.

Accurate metering and reliable operation

Hydrogen dispenser level control system is adopted, with LCD screen to automatically display parameters such as filling volume, cumulative filling volume, filling pressure, filling temperature, etc.

With high-precision mass flow meter, temperature and pressure compensation are setted, the measurement error is ≤0.5%, repeatability is ≤1%.

The inlet is equipped with large flux filter of 5μm precision to prevent impurities from entering.

Modular and integrated design

The modular and symmetrical design with standard internal pipe and valve fittings can ensure quick product delivery.

Most pipe and valve fittings are internally integrated to greatly prolong service life.

Multiple security mechanisms

With protective function of filling pressure limitation, filling process will automatically stop when the pressure value is meet.

Independent self-leakage detection technology, automatically monitoring hydrogen leakage.

The unloading hose is equipped with a pull-off valve, a protective sleeve and an anti-dumping device; the unique 0.2m guide hose ensures that the pull-off valve can work smoothly.

Technical Parameters (standard configuration)

Process gas

Hydrogen (99.99% purity)

Design pressure

25MPa

33MPa

Working pressure

20MPa

30MPa

Design temp.

-20-60℃

Length of guide hose

0.2m

Length of discharge hose

≥5m

Interface spec.

CGA1350 (connected to hydrogen cylinder trailer) or customized

Interface type

Double ferrule/ C&T

Interface qty.

Single or dual interface

Purge and replace function

DBB design, avoiding hydrogen backflow into the nitrogen pipeline.

Filtration accuracy

5μm (inlet filter)

Explosion-proof level

≥ExdⅡCT4 GB

Dimension, L×W×H（mm）

~1690×766×1780

HRS Solutions

Our solutions primarily encompass the supply and installation of a whole set of HRS equipment, complemented by a customized design of construction plan that aligns with the specific requirements of each site.

We tailor the deployment of our proprietary equipment to fit the scale and specific needs of each HRS. For instance, we perform in-depth calculations that factor in the refueling frequency, timing, and vehicle types, and select the most suitable equipment and parameters to yield maximum performance while minimizing energy consumption. The key equipment deployed at these stations include our specialized hydrogen compressor, dispenser, supply cabinet, cascade control cabinet, nitrogen cabinet, and filling cabinet. We independently design and assemble all the equipment to ensure its quality and reliability.

For a certain number of HRSs, we extend our services beyond mere site construction to include ongoing operation and maintenance support. Through over 8 years of development, we have accumulated extensive experience and established a proficient team specializing in the operation and maintenance of HRSs. We have also formulated a set of standardized guidelines and protocols, particularly in terms of equipment operating manuals, record management, emergency plans, and equipment maintenance practices, to ensure the stability, safety, and efficient operation of the stations. We stand out in HRS for our unique and integrated ability in providing customized solutions for the design, installation, and operation of HRSs.

Use Case

We undertook an HRS project in 2022 to design, install, and operate the world’s largest HRS with a refueling capacity of 6,400 kg H₂ per day.

Our customer was a major coal storage and transportation company in the city of Qiangan, where the customer had mostly used the hydrogen by-product from coke oven gas as fuel gas, which provided low economic value-add. The customer then planned to deploy a PSA purification system to generate hydrogen with a purity of 99.999%. Leveraging the PSA system, their plan called for the construction of a 35MPa HRS with a daily refueling capacity of 6,400 kg H₂ to sufficiently provide hydrogen to its own 200 heavy-duty trucks as well as to filling business.

Customer
pain points

The use of hydrogen-heavy tail gas as fuel gas generated a huge waste. With a PSA purification system in place, it can provide high added value hydrogen to HRS and filling business.

Lack of operation experience with a 24-hour HRS operation which would require both optimal selection of equipment and coordinated control, causing safety and operation concern.

Needed a solution that could help reduce the large-scale capital investment and occupancy of land.

Struggled to achieve a scenario of both rapid refueling and simultaneous refueling with large number of hydrogen-powered heavy-duty trucks.

Our solution

In our solution, the overall HRS was designed to have a capacity to handle 3,000Nm³/hour and 6400kg H₂ per day. Our focus was to help our customer to enhance the economic valves of tail gas where it will be able to provide sufficient low-cost and high purity hydrogen source for local communications using hydrogen energy.

On the hydrogen filling side, a combination of 4 (one standby) 1,000Nm³/hour and 22MPa diaphragm hydrogen compressors and refilling cabinets were configured to achieve three-route refilling simultaneously.

On the hydrogen refueling station side, 2 sets of 22MPa hydrogen storage cylinder assemblies were configured to provide buffering H₂ sources, with total water capacity at 28m³ and hydrogen storage capacity at approximately 413.56kg.

4 sets of 550kg/12h@12.5MPa and 45MPa discharge compressors were adopted.

4 hydrogen storage cylinder assemblies of 45MPa were used to ensure rapid refueling, with total water capacity at 42m³ and hydrogen storage capacity at approximately 1,212.83kg.

4 sets of dispensers with total 6-route to achieve simultaneous large volume refueling.

The successful construction of this world’s largest HRS equipped our customer with large-scale hydrogen filling and refueling capability, and its bottlenecks are effectively resolved.

With the integration of both filling and refueling capabilities, the station was able to elevate the economic values of the hydrogen, generating economic returns for our customer.

The skillful use of buffering capacity of the 22 MPa hydrogen storage cylinder assemblies effectively provided high inlet pressure for 45 MPa compressors, significantly increase the discharge capacity of the compressor.

The end results

Modularized operation and control were achieved through optimized equipment combination, enabling more stable equipment operation. A 6-route simultaneous and rapid refueling using 4 hydrogen dispensers became a reality.

The configuration of total 6-route simultaneous hydrogen refueling dispensers with cooling system, the flow regulating function and the proper pre-cooling design all ensured the refueling speed to reach 2.5–3.6kg/min, thus enabling the speedy filling and refueling of the whole station.