Sundyne’s PPI Diaphragm Compressors have been deployed at Hydrogen Refueling Stations around the Globe since 2001
Hydrogen Refueling Stations (HRS) for industrial vehicles are commonplace in Europe. They’re growing in popularity across the globe, as auto manufacturers (such as Toyota) expand and improve designs for passenger cars that run on Hydrogen.
Today, the range for H2-powered vehicles is approximately 500-700 KM (300-425 miles). This requires a tight mesh of Hydrogen Refueling Stations. Each HRS uses an Electrolyser to split water into hydrogen and oxygen (via electrolysis) to create and to store hydrogen fuel.

Electrolysers typically make Hydrogen at 20 to 30 bar. But H2-powered vehicles are rated for 350 to 700 bar. Sundyne compressors are used to compress the Hydrogen gas to make up this difference. Di-hydrogen is one of the smallest molecules on the planet, weighing no more than 2.02 grams per mole (whereas ambient air is close to 29 g/mole). The amount of work required to compress H2 from 20 bar to 700 bar is high, compared to a traditional mix of hydrocarbon gases.

This is one of the areas where Sundyne’s PPI compressors excel. They’ve been specifically designed to compress hydrogen, and Sundyne has learned much over the last 20 years serving this market around the globe.
Safety First: 

Diaphragm compressors are the preferred compression equipment for applications where environmental safety and gas purity are of primary concern. Their basic design provides leak tight and non-contaminating gas compression. PPI compressor’s self-energizing static O-ring seals in the head assembly prevent process gas leakage. Highly sensitive leak detection & containment capabilities provide the highest level of safety available on the market.

High Efficiency:  

PPI compressors achieve compression ratios of 10:1 per stage through careful control of the contoured cavities and clearance volumes. PPI’s 2 stage units use a 180 degree piston offset between each stage of compression - when one head is on the discharge stroke, the second head is on the suction stroke. This results in the highest possible efficiency and lowest power consumption.

Reliability – 24X7:
A refueling station must be on-line 24/7. Sundyne’s PPI compressors are purpose-built to specifically address the demands of Hydrogen refueling stations. They leverage the latest technology in solids modeling and FEA analysis, and all of the working components have been rigorously tested for reliability and longevity.
  • The PPI reciprocating frame is designed for a 20,000 lb (9,070 kg) rod load rating.  The machine has an oversized crankshaft and crankshaft bearings, and it uses heavy duty roller bearings with a BDC of 550,000 lb.
  • PPI’s Conservative (oversized) design for the wrist pin offers an L-10 life in excess of 500,000 hours.
Longer Mean Time Between Maintenance Intervals:
The replacement part life for compressor components is directly related to operational speed. PPI units typically operate in the range of 300-325 rpm.  Other manufacturers’ compressors run at much faster speeds, which requires maintenance more frequently, and often results in down time. 

Field Proven Experience – and World Class Support:

Sundyne’s PPI compressors have an extensive track record of high capacity, large diaphragm size machines in demanding applications requiring high up-time.  Sundyne’s support network offers the broadest coverage in Europe and through the globe.  As the demand for Hydrogen Refueling Stations grows, Sundyne is ready to deploy service techs quickly anywhere and everywhere around the globe, to help keep fueling stations open.

To download a copy of our Sundyne PPI Diaphragm Compressor Brochure, please completed the form below.  We will email a link directly to you.

 Sundyne World Headquarters  |  14845 W. 64th Ave.  |  Arvada, CO 80007  |  USA  |  +1 303-425-0800