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Mobile hydrogen filling stations

Compact and ATEX-compliant valve technology – The cooperation with Wystrach

Benefit from an ATEX-certified complete solution:

  • Reliable processes: No matter whether cold or heat – all components function reliably and are housed in conformity with ATEX.
  • Particularly space-saving: The pneumatic control cabinets are extremely slim and offer sufficient space for all components.
  • Individualised solution: No two systems are the same – optional assemblies in the control cabinet provide the necessary flexibility.
  • Everything from a single source: Bürkert not only supplies pneumatic valves, but also sensors and I/O systems, for example.

ATEX control cabinets for the optimum distribution of hydrogen guarantee the correct pressure balance

Hydrogen is regarded as an environmentally friendly energy carrier of the future because it can be used very flexibly, can be produced with renewable energy technologies and can be easily transported and stored. When hydrogen is used in fuel cells, no environmentally relevant exhaust gases are produced, only water.

The interreg-supported project H2-Share promotes the use of hydrogen in order to make a practical contribution to reducing emissions from heavy goods traffic. As part of the project, Wystrach developed the WyRefueler – a mobile hydrogen refuelling station that is currently being tested in international field operations. When filling the fuel containers and during the actual refuelling process, Bürkert valves make an important contribution.

The WyRefueler is a low energy consumption refuelling system for filling hydrogen tank systems. Whether buses, lorries, trains, construction machinery or forklifts: Any compressed hydrogen-powered vehicle can be refuelled with it.

WyRefueler Wystrach

Source: Wystrach GmbH


Hydrogen filling station for commercial vehicles


As a partner in the H2-Share project, Wystrach GmbH, a specialist in high-pressure gases, has developed the WyRefueler, a mobile hydrogen filling station. The user-friendly and approved system comes with a comprehensive consulting and service package and can be operated independently after appropriate training. It is suitable for 350 bar refuelling of a wide range of commercial vehicles, from trucks and vans in the logistics sector to construction machinery and hydrogen-powered buses and trains. The two-part system consists of a tank container as the main storage for the hydrogen and the actual filling station container where the vehicles are refuelled. Both components can be transported with an ADR trailer.

The tank container with a useful volume of 313 kg contains hydrogen in 54 special containers with a capacity of 350 l each at a pressure of typically 300 bar. The filling station container has a buffer storage of 88 kg at a pressure of 500 bar, a hydrogen compressor and an automatic pressure control for optimal refuelling. The removal capacity is 180 kg per day, but can be extended up to 360 kg if required. Both containers are connected to each other via interfaces for control technology, media flow and compressed air.





Valve technology for rapid refuelling

Correct pressure equalisation is important so that hydrogen can be refuelled quickly and safely at the filling station and for the self-optimisation of the system. This also applies when the tank container is filled with hydrogen at the filling station. In order to be able to reproduce all these cases, pneumatically controlled valves ensure the optimal distribution of the hydrogen in the container's tanks.

Other technology includes sensors, e.g. for temperature and pressure, corresponding I/O systems and the pneumatic valves that precisely switch the media-carrying valves and thus ensure the correct pressure balance. All components must function reliably in mobile use, both in summer heat and in winter cold, and must also be housed in an ATEX-compliant manner.

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The complete solution from a single source convinced us just as much as the intensive exchange and good cooperation during the development phase.

Gerwin Müskens, Technical Product Designer at Wystrach

(Source: Wystrach GmbH)

"After we had decided on Siemens for the controller and the decentralised peripheral system (SIMATIC ET 200iSP), we quickly came across Bürkert when looking for the right valve technology because the fluidics specialists are at home in this environment and have the corresponding know-how", Müskens continues. But there were other reasons as well: the wide range of pneumatic valves and the possibility of being able to accommodate all the components required for pressure compensation in ATEX-compliant, ready-to-connect control cabinets.


Slim control cabinets


The pneumatic control cabinets for use in the respective Ex zone are designed to be as slim as possible. Nevertheless, they offer sufficient space for the decentralised I/O system and a compact valve cluster with the required Ex-i valves Type 6518, which are installed on a mounting rail and wired on the Siemens ET 200iP. In addition, there are emergency stop and pilot valves. The necessary peripherals, including the pilot-operated solenoid valves, are also housed in the ATEX control cabinets. These are suitable for large flow rates, operate without constant air consumption and also impress with their low electrical power consumption.

The concept and the know-how in control cabinet construction convinced the high-pressure specialists, especially since Bürkert was also able to design and manufacture an ATEX-compliant housing "to measure" for the filling station's operating terminal and supply it with the corresponding certificate. Further joint projects are therefore not ruled out for the future.



Compact valve cluster with Ex-i valves Type 6518