With a transition towards a lower-carbon future, hydrogen technology has gained significant traction across numerous sectors. And the journey of hydrogen, from production to application, relies heavily on a crucial piece of equipment—the pump.

Pumps in hydrogen industry play a vital role in the safe and efficient transportation of this volatile gas. Whether moving hydrogen through electrolysis skids or circulating it within industrial processes, specialized pumps are the workhorses that keep the hydrogen revolution in motion.

We’ll discuss the design structure of hydrogen industry pumps and their manufacturing techniques, like sheet metal fabrication vs CNC machining. You’ll also learn about the use of common materials in engineering pumps to secure safe and sustainable operations. 

What are Pumps in Hydrogen Industry?

Hydrogen pumps are engineered to efficiently handle the unique properties of hydrogen gas, ensuring its proper flow and supply within fuel cell systems. Their primary function is to circulate hydrogen throughout the system, facilitating critical processes such as compression, storage, transportation, and distribution.

High-Pressure Hydrogen Pumps: At the heart of a hydrogen engine lies the high-pressure hydrogen pump. It’s responsible for pressurizing the hydrogen gas, making it suitable for fuel cell use. It takes the hydrogen from the storage tank and increases the pressure to the desired level.

Hydrogen Recirculation Pumps: Another essential component in a hydrogen fueling station is the hydrogen recirculation pump. This pump optimizes the efficiency of the fuel cell system by recirculating the unused hydrogen gas back into the system.

Hydrogen industry pumps find widespread use in other sectors too, such as powering industrial vehicles, off-grid systems, handling methane, etc.

Structures of Pumps in Hydrogen Industry

A hydrogen pump structure consists of three main components—a housing, impeller, and motor. Let’s discuss how these parts function to keep the pumps running:

1. The Housing

Imagine a sturdy container. That’s the basic function of a pump’s housing. 

This robust component forms the mainframe, cradling the impeller and acting as a secure vessel for the hydrogen. 

The housing is built to withstand the pressure changes and potential wear associated with fluid flow.

2. The Impeller

An impeller is basically a spinning fan with strategically designed blades. Its rotating set of blades churn the hydrogen within the housing. 

As the impeller spins, it creates low pressure on one side, drawing in hydrogen. Simultaneously, it pushes hydrogen towards the outlet on the other side, creating a continuous flow.

3. The Motor

A pump’s motor works like the muscle of the machine. It can be an electric or hydraulic device that provides the necessary energy to rotate the impeller. 

The motor’s power directly affects the flow rate and pressure at which the hydrogen is delivered. By adjusting the motor’s output, engineers can precisely control the movement of hydrogen within the system.

Manufacturing Techniques for Pumps Components

What goes into hydrogen pump manufacturing? We’ll discuss the manufacturing techniques used to create these specialized components.

1. CNC Machining

CNC (Computer Numerical Control) machining has an important role in the production of hydrogen pump components. The method is important for:

i. Precision

Housing: CNC machines ensure pump housings are crafted with unmatched accuracy. It guarantees tight tolerances and a high-quality finish. 

Impeller Excellence: Impellers, the heart of fluid movement, demand intricate geometries. CNC machining delivers the precision needed to create these complex shapes.

ii. Strength and Accuracy

Shafts & Rotors: Precision CNC machining crafts pump shafts and rotors to exact specifications. These critical components benefit from superior precision, which helps with producing a durable and reliable machine. 

Flawless Connections: Flanges and connectors keep pumps functioning seamlessly. CNC machining parts have the perfect accuracy and consistency, guaranteeing a leak-proof system.

iii. Innovation and Customization

Prototyping: CNC machines are invaluable for creating prototypes of new pump designs. This allows engineers to test and refine their ideas with remarkable precision.

Tailored Solutions: Every application has its unique needs. Advanced CNC technology allows for customization of pump components, such as impeller size or material, to perfectly match the demands of a specific project.

2. Sheet Metal Fabrication

Precision sheet metal fabrication is another technique to produce pumps in hydrogen industry. What is offers are:

Strength and Endurance: Sheet metal, particularly stainless steel, offers unprecedented strength and durability. It can handle the demanding environments hydrogen pumps operate in, resisting rust, corrosion, and keeping maintenance needs low.

Lightweight Advantage: Compared to some traditional materials, sheet metal offers a significant weight advantage. As a result, it becomes possible to build lighter, more efficient hydrogen pumps.

Material Versatility: Sheet metal fabricating isn’t limited to just one type of metal. Here’s a toolbox of options:

• Stainless and alloy steel provide high-strength and erosion-resistant properties for heavy-duty pumping.
• Cold-rolled steel offers a budget-friendly option for less demanding applications, up to a thickness of 3 mm.
• Grade 316 stainless steel tackles hotter environments while maintaining strength and corrosion resistance.
• Carbon steel is highly resilient, withstanding harsh conditions, extreme temperatures, and heavy loads.

Custom fabrication is effective for creating hydrogen pump components that are strong, lightweight, and adaptable to various needs. 

3. Metal Casting

Another technique used in hydrogen pump manufacturing is metal casting. The process involves pouring molten metal into a mold to solidify it into a pump component. It creates parts that are strong, corrosion-resistant, and perfect for managing hydrogen. Plus, casting is often more cost-effective than machining from solid metal.

Different pump components require custom metal casting techniques. Here are a few popular choices:

Lost Wax Casting: The method is ideal for intricate parts like pump housings made from stainless steel. It delivers smooth surfaces and tight tolerances, minimizing machining needs.

Aluminum Die Casting: Perfect for thin-walled components like mounting brackets. Aluminum die casting produces high-strength parts with excellent quality, ideal for specific wall thickness requirements.

Sand Casting: A cost-effective option for pump bodies made from iron or cast iron. Sand casting offers good internal quality but may require more machining compared to other methods.

Comparison of Hydrogen Pump manufacturing Techniques

Manufacturing Technique	Description	Advantages	Disadvantages	Suitable for
CNC Machining	Highly precise machining for complex components.	Unmatched accuracy and prototype creation	Higher cost	Housings, impellers, shafts, rotors, flanges, connectors
Sheet Metal Fabrication	Forming and assembling metal sheets for pump components.	Create strong, durable, and lightweight parts	Limited to simpler shapes and may require additional finishing	Housings, panels, brackets
Metal Casting	Pouring molten metal into a mold to create pump components.	Cost-effective for large volumes	Lower precision and more post-processing needed	Housings, pump bodies, some impellers

Materials for Pumps

From stainless steel to specialized polymers, the right choice of materials can make all the difference in a hydrogen pump structure. Let’s discuss the USP of each material in handling the unique challenges of hydrogen transportation and supply. 

1. Stainless Steel

The metal is ideal for various hydrogen system components, from storage tanks to piping and fuel cells. Its plus points are: 

i. High Endurance 

Hydrogen pumps operate under demanding conditions—high pressure, extreme temperatures (both hot and cold), and constant exposure to hydrogen gas. Stainless steel can withstand all these things, thanks to its superior strength and resistance to corrosion.

ii. Extreme Temperature Resilience

Whether dealing with the frigid temperatures of cryogenic storage or the heat generated during operation, stainless steel maintains its integrity. This makes it a versatile material for various components within a hydrogen system.

iii. Long-lasting Performance

Nobody wants a hydrogen pump that needs constant replacing. Stainless steel boasts a long service life, minimizing downtime and keeping those life-cycle costs low.

There’s an added bonus: hydrogen embrittlement, a phenomenon where hydrogen weakens some metals, isn’t a major concern with stainless steel. It ensures the pump components stay strong and functioning.

2. Titanium

Titanium is another choice for building pumps in hydrogen industry. Here’s why titanium shines:

• Unlike regular steel, titanium isn’t fazed by harsh environments. It shrugs off corrosion, even in high-chloride settings, ensuring a longer pump lifespan.
• Imagine a material that’s strong but surprisingly light. That’s titanium. So, titanium pumps are both powerful and easy to handle.
• Hydrogen pumps are constantly under pressure. Titanium’s superior elasticity allows it to bounce back and keep working efficiently.

Titanium parts can last a decade longer than their steel counterparts in tough environments. This makes them ideal for the chemical and process industries, where tasks like handling corrosive liquids and injecting high-pressure additives are commonplace.

3. Carbon Fiber Reinforced Polymers (CFRP)

Carbon Fiber Reinforced Polymers (CFRP) offers a promising combination of lightweight, strength, and corrosion resistance, making it a valuable material for next-generation hydrogen pump designs.

The material could be a good choice for hydrogen pump structure because: 

• CFRP boasts a high strength-to-weight ratio. This translates to a lighter pump, reducing energy use and wear on surrounding components.
• Hydrogen can be unforgiving on materials. CFRP’s natural resistance to corrosion ensures the pump’s integrity.

4. Polymer-based Materials

These versatile materials offer exciting possibilities for hydrogen pump construction.

Lightweight thermoplastics, like acrylonitrile butadiene styrene (ABS) and polyether ether ketone (PEEK), can be used for impellers to reduce pump weight and boost efficiency. 

On the other hand, ultra-resistant plastics, like ultra high molecular weight polyethylene (UHMW-PE) and perfluoroalkoxy polymer (PFA), stand up strong against corrosive properties of hydrogen.

5. Composite Materials

These non-metallic materials are making waves in pump technology for a few key reasons:

• Compared to traditional materials, polymers boast lower friction coefficients. As a result, the pump’s internal components get less wear and tear.
• Less friction also means fewer mechanical failures. With polymer components in place, you can expect reduced downtime and improved overall efficiency for a hydrogen pump.
• Shedding weight is always a plus, especially in machinery. Certain polymer composites can achieve this without compromising on strength. 

Conclusion

Pumps in hydrogen industry play a critical role in ensuring a safe, efficient movement of hydrogen gas throughout various applications. By utilizing advanced CNC machining, metal fabrication, casting, and high-performance materials like stainless steel, titanium, carbon fiber, and polymers, pump manufacturers can create durable and cost-effective components. As hydrogen technology continues to evolve, advancements in pump design and materials promise an even brighter future for clean energy.

Want to be at the forefront of the global hydrogen revolution? Zintilon’s precise CNC machining and metal fabrication can deliver high-quality hydrogen pump components. Our cutting-edge production capabilities are ready to supply the reliable equipment. Contact Zintilon to discuss your project needs.