This week at the Hannover MESse, Bosch Rexroth announced that, in collaboration with other companies in the hydrogen industry, it has developed a portfolio of scalable servo-hydraulic drives for compressors in the power range of 10 to 280 kW.
Hydrogen produced from renewable energy sources plays a key role in meeting global climate goals. It is a zero-CO2 alternative to fossil fuels and is particularly suitable for commercial vehicles. However, the experience of the electric vehicle transition shows that a comprehensive charging infrastructure is essential if the new technology is to succeed.
Over the next six years, thousands of hydrogen refueling stations will be operational worldwide, and Europe will lead the way, making an important contribution to decarbonizing the transport sector.
According to the EU's decision, by 2030, hydrogen refueling stations for cars and heavy commercial vehicles must be installed every 200 kilometers in all city hubs and along the Europe-wide transport network. The US has also set ambitious goals for itself. The Fuel Cell and Hydrogen Association predicts that the United States will need about 4,300 hydrogen fueling stations by 2030. "With our new technology solutions and close cooperation with our partners in the hydrogen energy industry, we can provide excellent support for achieving these goals," said Dr. Steffen Haack, Chairman of the Executive Board of Bosch Rexroth AG.
Hydrogen filling is technically much more complicated than gasoline and diesel filling stations or electric vehicle charging stations. The challenge: Hydrogen is either stored on site in liquid form (-253°C) or in gaseous form in tanks with different pressure levels. In order to gas a vehicle, hydrogen must be compressed in a controlled manner to between 700 and 900 bars. This requires a robust drive for the compressor.
The company adopts servo hydraulic drive technology and is equipped with stepless hydrostatic transmission. Rugged hydraulic system with long service life. The long-travel, ATEX-certified compressor drive cylinder increases the transfer rate with optimized control of the terminal position. The product portfolio covers the power range between 10 and 280 kW and a variety of applications.
New cryogenic pump: 100 kg hydrogen in 10 minutes
Bosch Rexroth has developed a new electro-hydraulic cryogenic pump in partnership with FirstElement Fuel, the market leader in the commercial operation of hydrogen refueling stations in the United States. The pump is connected with a power rating of 280 kW and compresses liquid hydrogen to 875 bar for direct refueling of heavy trucks. The goal is to fill the vehicle with 100 kilograms of hydrogen in 10 minutes. With direct hydrogenation, temporary storage tanks are not required at the hydrogenation station. The first hydrogen stations will be equipped with the new system starting in 2025.
The standard modules are finely extensible in both hardware and software
To achieve optimal energy efficiency, Bosch Rexroth relies on emission control. Unlike the throttle control used in most industrial hydraulic systems, position and force control is achieved through servo hydraulic pump control. This control concept can reduce energy consumption by approximately 75%. In addition, the compressor's drive system requires less than one square meter of installation space and is much quieter than conventional drive systems. Once parameterized, they are ready for immediate use. They communicate with the control system of the hydrogen refueling station through an open interface. All modules continuously record operational data, enabling systematic condition monitoring and predictive maintenance, as well as maximum availability through the digital service CytroConnect Solutions.
Bosch Rexroth can configure the standard drive hardware and software in its portfolio according to the specific application to precisely meet the needs of the user. The compressor drive system simplifies the system architecture and operability of the hydrogen station, making it suitable for both established companies in the hydrogen industry and new entrants.
Bosch is developing technologies for hydrogen production, compression, storage and use throughout the value chain. By 2030, Bosch aims to achieve a turnover of around 5 billion euros through this business unit. Between 2021 and 2026, the company will invest a total of around 500 million euros per year in the development and production of H2 technology.
