A containerised hydrogen station is designed for on-site production of hydrogen (and possibly oxygen) at the client’s facility. The hydrogen unit is pre-assembled and tested at the manufacturer’s site, and delivered ready for operation. The main advantages of this solution are rapid deployment and mobility. The container houses all necessary technological equipment and can be transported by road or rail and installed at the desired location.
The core equipment of a containerised hydrogen station is a hydrogen electrolyser, which uses electric current to split water into hydrogen and oxygen. The system may additionally include purification and drying units, water treatment stations, cooling systems, power distribution equipment, high-pressure compressors, and other necessary components.
Process Description
Hydrogen and oxygen in the electrolysis units are generated from demineralised water with a conductivity of 5 μS/cm. The lifespan of the hydrogen generation system depends on water quality and maintenance. Salts and organic compounds in untreated water can quickly damage the membranes and electrodes in the electrolyser cells. Special attention is given to the use of reverse osmosis membranes to prepare water for electrolysis. These membranes remove salts and other impurities, producing demineralised and highly purified water suitable for the electrolyser.
Purified water is then mixed with an alkaline electrolyte in the electrolyser. When a direct current passes through the electrolyte, water undergoes electrolysis, splitting into two parts: hydrogen and one part oxygen. Hydrogen is collected and sent for further purification, while oxygen can be separated and used in other processes or released into the atmosphere. Production output is controlled by adjusting the direct current through the electrolyte.
Containerised hydrogen stations can be equipped with hydrogen refuelling systems for cylinders (up to 200 bar) or storage tanks (up to 400 bar). This allows hydrogen to be stored safely and conveniently for transport. Such systems are particularly useful for supplying hydrogen to the market and for its use in various sectors, such as transport, energy, and other industries where hydrogen is an important energy source.
If equipment redundancy is required, the project can include a receiver park or cylinders for compressed hydrogen storage. In the event of equipment failure, hydrogen will be supplied to the network from the storage cylinders as a backup source.
Advantages of Containerised Hydrogen Stations
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Mobility
These stations are highly mobile and can be quickly deployed and relocated. This allows use in remote areas without access to conventional energy sources. Container mobility also provides flexibility in station placement according to demand and changing conditions.
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Flexibility
Containerised stations offer flexibility in configuration and scaling. They can be adapted for different production capacities. Thanks to their modular design, container blocks can be added or removed depending on changing requirements, allowing efficient resource use and scalable hydrogen production.
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Rapid Deployment
The containers are ready-made modules that can be quickly installed and connected. This allows fast deployment of hydrogen production and usage, particularly in situations requiring urgent energy supply, such as natural disasters or temporary events.
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Independence from Logistics
Containerised stations reduce reliance on externally supplied hydrogen, which is especially useful in remote regions where cylinder delivery may be limited or unavailable.
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Environmental Efficiency
Hydrogen production via electrolysis emits no harmful pollutants and can be powered by renewable energy. On-site production and use reduce transportation costs and greenhouse gas emissions.
Overall, containerised hydrogen stations are a promising solution for hydrogen production and use across various sectors. Their mobility, flexibility, and environmental efficiency make them an attractive option for both hydrogen production and storage.
Technical Specifications
The technical specifications of a hydrogen unit may vary depending on the specific project and application requirements. Different types of electrolysers and storage systems can be used to achieve optimal performance, efficiency, and safety. Key parameters may include:
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Production Capacity
This is the amount of hydrogen an electrolyser can produce over a given period. Capacity can be measured in m³/h or kg/h. The production capacity of a hydrogen station depends on its size and the type of electrolyser used. Our company offers stations with a minimum capacity of 1 m³/h.
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Hydrogen Storage System
Hydrogen, being a light and high-energy gas, requires specialised storage systems to ensure safety and efficiency.
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High-Pressure (gas cylinders)
Hydrogen can be compressed to high pressure and stored in gas cylinders made of durable materials such as composites or steel. Cylinder volumes and pressures vary depending on requirements. This system provides mobility and convenience but requires space and may have limited storage capacity.
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Liquid Hydrogen (cryogenic tanks)
Hydrogen can be cooled to extremely low temperatures (–253 °C) and stored as a liquid in specialised cryogenic tanks. Liquid hydrogen provides high storage density and allows large volumes to be stored in relatively compact containers. However, this requires complex cooling and insulation systems, as well as special safety measures when handling extremely low temperatures.
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Operating Pressure
This is the pressure at which hydrogen can be supplied or stored. Operating pressure is usually expressed in bars or kgf/cm² and may vary depending on the specific application. Typically, the operating pressure ranges from 5 to 400 bar.
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Hydrogen Purity and Oxygen Content
Hydrogen produced by electrolysers typically has a purity of 99.5 % vol. This purity can be slightly lower with very low oxygen content. Oxygen content in the produced hydrogen may be less than 5 parts per million (ppm), or even below 1 ppm, making electrolytic hydrogen extremely pure and suitable for many applications.
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Moisture Content
Hydrogen electrolysers can produce hydrogen with very low moisture content. However, even when using high-quality distilled water, a small amount of moisture may remain in the hydrogen. Additional purification or drying systems are usually required to remove residual moisture.
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Impurities
Hydrogen produced may contain minor impurities such as nitrogen, methane, carbon dioxide, and other gases. Modern hydrogen generators typically include purification and filtration systems that remove these impurities and ensure high hydrogen purity.
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Each storage system has its advantages and limitations, and the choice depends on specific application requirements. Factors such as storage volume, mobility, safety, and efficiency should be considered when selecting a hydrogen storage system.
Explosion Protection for Modular Container StationsExplosion protection for modular container stations may include the following measures:
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Use of Explosion-Proof Components and Materials
During the design and manufacturing of blocks and modules, it is important to use specialised explosion-proof components and materials. This may include explosion-proof electrical components, anti-static materials, and other protective measures.
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Installation of Automatic Fire Suppression Systems and Gas Detectors
Safety can be ensured by installing automatic fire suppression systems and gas detectors. These systems can detect the presence of explosive gases and automatically stop equipment operation or activate fire suppression to prevent fire or explosion spread.
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Ventilation Systems
The interior of blocks or modules should be equipped with ventilation systems that comply with working area requirements, ensure proper air circulation, and prevent the accumulation of explosive gases. This may include forced-air ventilation and gas exhaust systems.
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Special Installation and Connection Methods
During assembly and connection of blocks and modules, special methods should be applied to prevent sparks or friction that could lead to explosions. This may involve explosion-proof motors, specialised connectors, and grounding methods.
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Maintenance and Service Program
A maintenance and service program should be developed and implemented, including periodic inspection and replacement of explosion-proof components and systems. Regular maintenance and checks help detect and eliminate potential hazards.
All these explosion protection measures ensure the safe operation of containerised hydrogen stations and prevent possible explosions or fires, safeguarding personnel and the environment when working with hydrogen.
About ONH Systems
ONH Systems develops and manufactures equipment for producing industrial gases, including hydrogen generators via electrolysis. The company’s engineering team has over 10 years of industry experience. The equipment complies with both Russian and international standards.
You can order the production of hydrogen generators and containerised hydrogen stations tailored to your specific requirements. For details, call +7 (495) 150-44-22 or email sales@onhs.ru — we will respond promptly and assist.