TYLER CAMPBELL, Managing Editor

H₂ EQUIPMENT

ACME Cryogenics adds XL Bore vacuum-jacketed piping to its portfolio of cryogenics handling products

ACME Cryogenics, a part of OPW Clean Energy Solutions, has added XL Bore Vacuum-Jacketed Piping (VJP) to its portfolio of cryogenics-handling products. The new XL Bore VJP has been designed to outperform typical foam-insulated piping in terms of maintaining the cryogenic liquid’s extremely cold temperature, leak prevention and high-volume transfer of the full array of cryogenics, from liquefied natural gas (LNG), liquid hydrogen (LH₂) and liquid oxygen (LO_X) to carbon dioxide (CO₂) and helium. 

ACME Cryogenics has a history of developing VJP systems with piping configurations ranging from 1/2- in. x 2 in. to 12 in. x 16 in. and has now created its first 16 in. x 18 in., 20 in. x 24 in. and 24 in. x 28 in. XL Bore VJP systems. Similar to foam-insulated piping, the VJP consists of a “pipe within a pipe” design with an inner pipe that carries the cryogenic liquid and an outer pipe that seals the annular space between the pipes. However, unlike foam-insulated piping, the inner pipe in a VJP system is wrapped with thin sheets of multi-layer insulation (MLI) that is coated with a metallic material, usually aluminum, that blocks radiative heat transfer. This design allows the VJP to operate maintenance-free for 20 yr or more. 

These pipes are built in 40-ft. “spools” (also called “sticks” or lengths) and shipped to the job site 15 at a time via transport trailer. Like all other ACME VJP systems, the XL sizes are engineered to offer superior insulation performance, minimize heat leaks, enhance operational efficiencies and be a more cost-effective solution than foam-insulated piping. Benefits to the user of XL Bore VJP systems include: 

• Higher flowrates for faster liquid transfer 
• Enhanced cryogenic cooling efficiency 
• Minimized heat leaks for improved operational efficiency 
• Superior performance when compared to traditional insulation methods 
• Full customizability to satisfy all cryogenic-liquid handling and transfer applications 
• Ability to handle a wide spectrum of cryogenic liquids, including LNG, LH₂, LO_X, liquid argon (LAR), liquid nitrogen (LIN), CO₂ and helium. 

For more information, visit: https://www.opwces.com/?utm_source=pressrelease&utm_medium=pressrelease&utm_campaign=XL_Bore_VJP&utm_content=pressrelease 

Metis Engineering launches advanced H₂ leak detection sensor for safety in energy storage systems

Metis Engineering, a leader in battery safety and monitoring innovations, has launched its latest breakthrough: Cell Guard with H₂. This new sensor, a sophisticated evolution of the original Cell Guard, is engineered to detect H₂ in energy storage systems, offering essential safety enhancements for both H₂-based applications and battery packs. 

In air, H₂ has a wide flammability limit from 4%─77% by volume and an explosive limit from 18%─59%. The activation energy for ignition is extremely low and can be triggered by a very small spark or static discharge. H₂ is an odorless, colorless gas and can go undetected without specialized technology. 

Early detection of H₂ leaks is critical to maintaining safety across the H₂ lifecycle—from production to storage, transport, use in fuel cells and H₂ internal combustion engines (ICEs). With applications spanning transport, marine, aviation and industrial sectors, Metis Engineering’s new sensor meets this critical need, creating new benchmarks for safety in H₂ technologies. 

The latest H₂ detection sensor addresses key safety needs with innovative, high-performance features, advancing on the foundation of the original Cell Guard sensor: 

• Reliable H₂ storage leak detection: This sensor offers unparalleled accuracy in identifying even trace H₂ leaks, ensuring compliance with the strictest safety standards and protecting against fire or explosion risks in H₂ storage systems. 
• Electrolysis detection in fuel cells and battery packs: Moisture ingress can lead to the electrolyzer producing dangerous gases. 
• Enhanced detection in high volatile organic compound (VOC) environments: Cell Guard with H₂ excels in environments with high VOC levels. For example, where large amounts of adhesive have been used in the construction of an energy storage system, ambient levels of VOCs can remain very high; this sensor can still detect thermal runaway. 
• Wider temperature range compatibility: With an expanded operational range of −40°C to 85°C (−40°F to 185°F), this sensor is built for extreme conditions, where other sensors may underperform, making it ideal for diverse, demanding environments. 
• Ultra-low power consumption: Operating in low power mode, Cell Guard with H₂ ensures continuous monitoring with little energy drain (< 1 mA). On detection of a level that matches a preconfigured threshold, Cell Guard with H₂ will wake the controller area network (CAN) interface and toggle a low-side drive pin, providing power efficient detection of H₂ leaks and water ingress. 
• Instantaneous measurement upon startup: The sensor delivers immediate H₂ measurements without the need for warm-up, ensuring real-time safety monitoring from power-up. 
• Wide accurate detection range of 0%–20% H₂: The sensor measures H₂ with precision across a wide range, offering dependable data in variable conditions. 

For more information, visit: https://metisengineering.com/product-category/production-sensors/production-sensor-range/ 

technotrans presents new compressed air-free spray lubrication system for bipolar plates

technotrans has introduced the new generation of its compressed-air-free spray lubrication systems. The focus is on the new spray.xact reflection with an extended spray width. The patented reflection method enables homogeneous micro-quantity lubrication of significantly less than 0.5 grams per square meter (g/m²) on ultra-thin sheets and coils. This makes the system ideal for, among other things, processing bipolar plates for H₂ production. 

Until now, the spray.xact reflection was available with two valves and a spray width of 200 mm. In the new generation, the system is equipped with additional valves and a significantly larger spray width. The special feature of the system is its patented process: the spray streams from above and below are reflected via a surface. This allows micro-quantities of significantly less than 0.5 g/m² to be applied to workpieces. The spray.xact reflection not only operates energy-efficiently without the use of compressed air, but also conserves resources as a closed-loop solution: the medium that runs off the surface is collected in an integrated tray and fed back into the system. Applications include the processing of very thin bipolar plates for H₂ production. 

For more information, visit: https://www.technotrans.com/home 

Distran releases gas leak imaging acoustic solutions

Sound is a highly regarded indicator by technicians to detect failures in industrial plants. During the inspection round, an experienced technician can compare the sound environment and determine whether something has changed (e.g., a growing gas leak).  

By automatically analyzing every surrounding sound, Distran devices are able to instantly map sound sources such as gas leaks from a safe distance. Listening to ultrasounds allows Distran Ultra M to disregard most of the normal background noise and focus on gas leaks. Distran Ultra M uses 128 ultrasound sensors combined with cutting-edge algorithms to analyze and locate gas leaks.  

The Ultra M ultrasonic camera was developed in power plants in close cooperation with the companies Alstom and General Electric and has been thoroughly tested and adapted to the high requirements. 

Finding leaks in power plants is not an easy task. Soap-spraying pipes or valves are time-consuming, and sometimes dangerous, yet necessary to guarantee the safe functioning of a power plant. With Ultra M, nearby gas leaks are instantly detected and displayed in real-time on the Ultra M screen. 

The reliability of a power plant is key to its profitability. Unplanned outages are costly because of the additional maintenance costs, the inability to sell energy, and due to grid penalties. Amongst the main causes of outages, leakage is a very common one with a high impact on power plant results.  

Distran Ultra M locates all leaks up to 20 meters distance within seconds, without being in contact with the gas. It works by detecting the ultrasonic signature of leakages due to the air turbulence created by the pressure drop. Ultra M locates leaks in the noisiest places, such as in gas turbine noise enclosures. One day is sufficient to cover the most critical elements in a power plant.  

Multiple gases are used in power plants (e.g., methane, compressed air, H₂). Ultra M can inspect your entire plant for leakages, regardless of the type of gas.  

Leaks can be detected from a several meters away, which reduces the need for climbing ladders or entering dangerous areas, thereby increasing the overall safety of the operator and reducing inspection time, not to mention the reduction of work permit necessity. Leak detection with Ultra M can be performed while machines are running, thus reducing the impact on operations.  

Equipped with the sensor head in its backpack, a single operator can perform the inspection. Ultra M works like a digital camera: the user sees the output in real-time on the screen. In a single tap, the operator can take a picture or video to keep track of the leak and easily generate a report. 

For more information, visit: https://distran.swiss/en/home/ 

H₂ PRODUCTION

Gradiant launches ProtiumSource, an electrolyzer-ready water solution, tailored to the needs of green H₂ producers

Gradiant, a global solutions provider for advanced water and wastewater treatment, has launched ProtiumSource, an end-to-end solution for electrolyzer-ready water. ProtiumSource enables producers to focus on green H₂ rather than source water. 

H₂ is a critical component in the planet’s transition to a carbon-neutral future, offering an alternative to the fossil fuels used in hard-to-abate industrial markets, including ammonia-based fertilizers, steel and chemical production, power and transportation. Green H₂ is produced with zero-carbon emissions, making it a highly desirable raw material for industrial uses. However, its potential as a fully renewable resource is only realized if the input water that yields the H₂ is also green. Gradiant’s ProtiumSource offers producers the solution they need to fulfill the promise of green H₂ by delivering high-purity, electrolyzer-ready water with the lowest energy demand, fully powered by renewable energy. 

ProtiumSource results from collaboration, combining the recently acquired H+E Group’s decades of ultrapure water expertise with innovation from the Gradiant Labs, to satisfy the urgent needs of green H₂ producers and excel in all operating environments: 

• Feedwater-agnostic: It delivers guaranteed high purity, electrolyzer-ready water from any feedwater input, including seawater, brackish water and treated wastewater, making it highly adaptable to operating environments with limited access to high-quality input water. 
• Zero liquid discharge: It mitigates the challenge of managing brine by recycling all water with the option to produce zero or minimal liquid discharge. 
• Industry-leading efficiency: Gradiant’s award-winning RO Infinity with CFRO technology delivers best-in-class performance with the lowest energy, reducing overall capital requirements for renewable energy infrastructure. 
• Lowest total lifecycle costs: From high-purity source water that exceeds the specified requirements for all electrolyzer systems, extending their usable life and reducing capital expenditure (CAPEX), operational expenditure (OPEX) and total lifecycle costs. 

ProtiumSource uses water treatment technologies in a fully integrated, balanced three-phase system that Gradiant tailors to the throughput needs of any green H₂ production plant: 

• Step 1—Water purification: It leverages Gradiant’s award-winning pretreatment, selective contaminant extraction and RO Infinity technologies to remove a complete range of inorganic and organic contaminants from any feedwater. 
• Step 2—Electrolyzer-ready source water production: It leverages H+E’s ultrapure water knowledge and experience in IX, EDI and UV technologies to yield electrolyzer-ready water that exceeds industry specifications. 
• Step 3—Integrated brine management system for ZLD: The company uses its award-winning RO Infinity with CFRO technology to reclaim water from brine at the pretreatment and high-purity stages for zero liquid discharge. 

For more information, visit: https://www.gradiant.com/solutions-and-industries/ 

H₂ APPLICATIONS INNOVATION

Siltrax launches silicon-based fuel cell technology

Siltrax has introduced its silicon-based fuel cell technology, which leverages the unique characteristics of silicon to deliver enhanced performance, durability and cost-efficiency. Supported by a $10-MM investment round, including $7 MM from Australia’s Clean Energy Finance Corporation (CEFC), Siltrax is focused on transforming the H₂ industry with its technology, designed to revolutionize fuel cell applications across a range of industries. 

At the core of Siltrax’s fuel cell technology are silicon-based bipolar plates, which take advantage of the material’s lightweight and durable nature, mechanical and chemical stability, and ability to withstand high temperatures and corrosive environments. Silicon also allows the creation of micro-scale flow channels on the plates’ surface. Combined, these attributes directly enhance the power density, durability and performance of Siltrax’s fuel cells relative to its competitors. 

Another key advantage of Siltrax’s innovation is its ability to leverage existing photovoltaic (PV) supply chains for raw materials and production equipment. This strategic approach also allows Siltrax to leverage existing process and techniques to further optimize its manufacturing processes, and holds the potential to reduce the overall cost of fuel cell production, making this advanced technology more accessible for widespread adoption. 

Siltrax’s initial focus is on aerospace and stationary power applications. H₂ is considered the optimal solution for decarbonizing the aerospace industry, as H2’s high energy density makes it a suitable medium for powering aircraft over long distances. Applications of Siltrax fuel cells include: 

• Drones and aerospace: Lightweight, compact silicon-based fuel cells are advantageous in applications where volume and weight are critical factors. This includes drones, electric vertical take-off and landing aircraft (eVTOLs) and other aerospace technologies that require high energy density without compromising payload capacity. 
• Stationary power generation: With its durability and low-cost manufacturing, Siltrax fuel cells are also ideal for stationary power applications, providing zero-emissions, reliable energy solutions. Additionally, Siltrax’s fuel cell solutions can integrate with existing natural gas and methanol infrastructure, reducing the need for high-purity H₂. 
• Transportation: Siltrax’s innovative fuel cells can be used for various transportation applications, including commercial vehicles and passenger vehicles. 

With backing from the CEFC and Virescent Ventures, Siltrax is expanding its research and development team in Australia to further advance fuel cell systems engineering and explore local commercialization opportunities. The company is focused on bringing this revolutionary technology to international markets, contributing to the global transition toward a cleaner energy future. 

Fuel cells, which directly convert the chemical energy in H₂ into electricity with only water and heat as byproducts, are crucial in the global transition to cleaner energy. The International Energy Agency (IEA) has identified fuel cells as one of the critical technologies necessary to meet the challenges of energy transition. 

For more information, visit: https://www.siltrax.net/products/

H₂ STORAGE AND TRANSPORTATION APPLICATIONS

NETL releases techno-economic tools to model H₂ pipeline transport costs

National Energy Technology Laboratory (NETL) has released two innovative cost models designed to calculate the expenses associated with transporting pure H₂ using new pipelines and natural gas blended with H₂ through existing natural gas pipelines. These critical tools will help stakeholders involved in the burgeoning H₂ economy make better-informed decisions that contribute to the nation’s decarbonization goals. 

For example, these tools could be used by entities involved in H₂ hub projects recently selected by the U.S. Department of Energy (DOE) and funded by the Bipartisan Infrastructure Bill. The hubs will accelerate the commercial-scale deployment of clean H₂ and help to generate clean, dispatchable power, create a new form of energy storage and decarbonize heavy industry and transportation. Accurate estimates of transport costs by pipeline could play a critical role in the success of these projects, where connecting H₂ producers with H₂ users is a key element of their success. 

The Office of Fossil Energy and Carbon Management (FECM)/NETL H₂ Pipeline Cost Model (H2_P_COM), is a Microsoft^® Excel-based tool that estimates costs for transporting gaseous H₂ in a new pipeline from a source, such as a H₂ production facility, to a final destination, which may be the user of the H₂ or a distribution center where H₂ in the pipeline is diverted to multiple end users. The user specifies input values, such as the average annual H₂ mass flowrate, capacity factor, pipeline length, elevation change along the pipeline, the number of compressor stations, years of operations and several financial variables, including the price charged to transport H₂. The model generates revenues and costs for the pipeline and calculates the net present value (NPV) for the project where an NPV greater than zero indicates the price charged is high enough to cover all costs including financing costs. 

The FECM/NETL Natural Gas with H₂ Pipeline Cost Model (NG-H2_P_COM), is a Microsoft Excel-based tool that estimates the costs of upgrading existing natural gas pipelines so the pipelines can be used to transport natural gas blended with up to 20%─25% H₂. The cost to upgrade an existing natural gas pipeline depends on the condition of the pipeline and the fraction of H₂ in the natural gas. If the percent of H₂ in the natural gas is < 5%, some existing natural gas pipelines can transport the mixture with no upgrades. For mixtures approaching 25%, an existing natural gas pipeline may require the replacement of all compressors and some pipe segments. The user of the model must specify the upgrades needed and the model will calculate the costs of the upgrades and the cost of operating the pipeline. 

As part of the development of NG-H2_P_COM, the development team released a document that compared results from NG-H2_P_COM with results from another techno-economic modeling tool developed by the National Renewable Energy Laboratory called BlendPATH. The two models were run with the same or similar inputs and the resulting costs and cash flows were compared. There was reasonable agreement of the results between the two models. 

The release of these two tools underscores the continual enhancement of NETL’s techno-economic analysis capabilities and supports the development of new supply chains and decarbonization technologies needed for the clean energy transition.

For more information, visit: https://netl.doe.gov/energy-analysis/search?search=NatGasHydrogenPipelineCostModel2024 

Researchers at ETH Zurich use iron to store H₂

Researchers at ETH Zurich are using iron to store H₂ safely and for long periods. In the future, this technology could be used for seasonal energy storage. Photovoltaics are set to meet > 40% of Switzerland’s electricity needs by 2050. However, solar power is not always available when it is needed: there is too much of it in summer and too little in winter, when the sun shines less often and impels heat pumps to run at full tilt. According to the Swiss federal government’s energy strategy, Switzerland wants to close the winter electricity gap with a combination of imports, wind and hydropower as well as alpine solar plants and gas-fired power plants. 

One way to minimize the need for imports and gas-fired power plants in winter is to produce H₂ from cheap solar power in summer, which could then be converted into electricity in winter. However, H₂ is highly flammable, extremely volatile and makes many materials brittle. Storing the gas from summer until winter calls for special pressurized containers and cooling technology. These require a lot of energy, while the many safety precautions that must be followed make building such storage facilities very expensive. In addition, H₂ tanks are never completely leak-proof, harming the environment and adding to the costs. 

Researchers at ETH Zurich led by Wendelin Stark, Professor of Functional Materials at the Department of Chemistry and Applied Biosciences, have developed a new technology for the seasonal storage of H₂ that is much safer and cheaper than existing solutions. The researchers are using a well-known technology and the fourth most abundant element on Earth: iron. 

To better store H₂, Stark and his team are relying on the steam-iron process, which has been understood since the 19th century. If there is a surplus of solar power available in the summer months, it can be used to split water to produce H₂. This H₂ is then fed into a stainless-steel reactor filled with natural iron ore at 400˚ C. There, the H₂ extracts the oxygen from the iron ore—which in chemical terms is simply iron oxide—resulting in elemental iron and water. 

The reactor in which the reaction takes place does not have to fulfil any special safety requirements. It consists of stainless-steel walls just 6 mm thick. The reaction takes place at normal pressure and the storage capacity increases with each cycle. Once filled with iron oxide, the reactor can be reused for any number of storage cycles without having to replace its contents. Another advantage of the technology is that the researchers can easily expand the storage capacity. It is simply a case of building bigger reactors and filling them with more iron ore. These advantages make this storage technology an estimated ten times cheaper than existing methods. 

However, there is also a downside to using H₂: its production and conversion are inefficient compared to other sources of energy, as up to 60% of its energy is lost in the process. This means that as a storage medium, H₂ is most attractive when sufficient wind or solar power is available and other options are off the table. That is especially the case with industrial processes that cannot be electrified. 

The researchers have demonstrated the technical feasibility of their storage technology using a pilot plant on the Hönggerberg campus. This consists of three stainless-steel reactors with a capacity of 1.4 m³, each of which the researchers have filled with 2 t–3 t of untreated iron ore available on the market.

For more information, visit: https://ethz.ch/en/news-and-events/eth-news/news/2024/08/iron-as-an-inexpensive-storage-medium-for-hydrogen.html H₂T