Learn how to use hydrogen fuel cells safely and effectively to power industrial machinery, based on mechanical engineering principles and insights.

There are different types of fuel cells. PEMFC - Proton exchange membrane SOFC - solid oxide to name a few. The overall reaction creates very high heat on the side of electricity. Since their efficiency is low, the thermal management is a key part of the fuel cells.

What are the best practices for using hydrogen fuel cells to power industrial machinery?

Hydrogen fuel cells are devices that convert the chemical energy of hydrogen and oxygen into electricity, water and heat. They are a clean and efficient alternative to fossil fuels, especially for powering industrial machinery that requires high power and reliability. However, using hydrogen fuel cells also involves some challenges and risks, such as hydrogen storage, safety, cost and durability. In this article, you will learn about the best practices for using hydrogen fuel cells to power industrial machinery, based on the principles of mechanical engineering.

1 How hydrogen fuel cells work

Hydrogen fuel cells consist of an anode, a cathode and an electrolyte membrane. Hydrogen gas flows through the anode, where it splits into protons and electrons. The protons pass through the membrane, while the electrons travel through an external circuit, creating an electric current. Oxygen gas flows through the cathode, where it combines with the protons and electrons to form water and heat. The overall reaction is H2 + 1/2 O2 -> H2O + electricity + heat.

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Beratcan Altuntaş

Aerothermal Engineer at GE Aerospace
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There are different types of fuel cells. PEMFC - Proton exchange membrane SOFC - solid oxide to name a few. The overall reaction creates very high heat on the side of electricity. Since their efficiency is low, the thermal management is a key part of the fuel cells.

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Shivkumar Shinde

Lead Member at Field Services
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Similar to batteries, a fuel cell is a device that converts energy stored in molecules into electricity through an electrochemical reaction. Composed of two electrodes (an anode and a cathode) separated by an electrolyte membrane, a typical hydrogen fuel cell works in the following way: Hydrogen enters the fuel cell via the anode. Here, hydrogen atoms react with a catalyst and split into electrons and protons. Oxygen from the ambient air enters on the other side through the cathode. The positively charged protons pass through the porous electrolyte membrane to the cathode.

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Daniel Ochiel

Mechanical Engineer at GOVERNMENT OF KENYA
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Here are some best practices for using hydrogen fuel cells to power industrial machinery: Select the right size and type of fuel cell Consider the machinery and application, including power demand, load profile, and operating conditions. Provide adequate ventilation This can minimize the risk of asphyxiation and the formation of combustible hydrogen/oxygen mixtures. Use special flame detectors Hydrogen burns with an almost invisible blue flame. Consult with experts Personnel with applicable expertise should be consulted in designing and implementing any system carrying a potential safety risk.

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2 Types of hydrogen fuel cells

There are different types of hydrogen fuel cells, depending on the electrolyte material and the operating temperature. The most common ones for industrial applications are proton exchange membrane fuel cells (PEMFCs) and solid oxide fuel cells (SOFCs). PEMFCs use a polymer membrane as the electrolyte and operate at low temperatures (50-100 °C). They have high power density, fast start-up and low emissions, but they also require pure hydrogen and expensive catalysts. SOFCs use a ceramic material as the electrolyte and operate at high temperatures (600-1000 °C). They have high efficiency, fuel flexibility and long lifespan, but they also require complex thermal management and long start-up.

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3 Benefits of hydrogen fuel cells for industrial machinery

Hydrogen fuel cells offer several advantages for powering industrial machinery, including reduced greenhouse gas emissions and air pollution, improved energy security and independence, enhanced performance and reliability, and increased flexibility and scalability. As a result of their clean emissions, they can use locally produced or renewable hydrogen sources. Additionally, their high power output, low noise and vibration, and minimal maintenance make them a reliable and efficient choice. Furthermore, they can be integrated with other energy systems, such as batteries, solar panels or grid connections.

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4 Challenges and risks of hydrogen fuel cells for industrial machinery

Hydrogen fuel cells pose several challenges and risks for powering industrial machinery, such as high capital and operating costs due to the need for expensive components like membranes, catalysts, compressors and storage tanks. Additionally, hydrogen is not widely distributed or standardized across regions and sectors, making it difficult to access. Furthermore, hydrogen is a flammable and explosive gas that requires careful handling, storage and transportation, posing safety and regulatory issues. Lastly, technical and environmental barriers like hydrogen leakage, corrosion, degradation and contamination of fuel cells and their components must be considered.

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5 Best practices for using hydrogen fuel cells for industrial machinery

To ensure the safe and efficient use of hydrogen fuel cells for industrial machinery, you should select the appropriate type and size of fuel cells for your machinery and application, taking into account factors such as power demand, load profile, and operating conditions. Additionally, you should choose the optimal hydrogen source and delivery method for your fuel cells based on availability, cost, and quality. You should also implement safety and quality measures for your fuel cells and hydrogen systems that adhere to relevant standards, codes, and regulations. It’s important to monitor and maintain your fuel cells and hydrogen systems regularly with advanced sensors, diagnostics, and control systems. Finally, you should evaluate and improve your fuel cells and hydrogen systems continuously using performance indicators, feedback mechanisms, and optimization tools.

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Tarig M. Elghazali , PMP®

Senior Project Engineer @ Saudi Electricity Company | PMP, Cost Engineer | Projects Planning & Scheduling
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I think the most important regarding hydrogen applications is that safety must be considered all the time and to avoid hazards and hazops, alot of sensors and leak detectors should be in place and functioning, also alot of equipment, fire spinklers, detectors and a lot of other facilities should be installed with main facility which increase engineering cost for most of industerial facilities.

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6 Future trends and opportunities of hydrogen fuel cells for industrial machinery

Hydrogen fuel cells have a great potential for powering industrial machinery in the future, as they can support the transition to a low-carbon and circular economy. Emerging trends and opportunities of hydrogen fuel cells for industrial machinery include developing new and improved materials, technologies and designs to reduce costs, increase performance and extend lifespan. Additionally, expanding and diversifying the hydrogen market and infrastructure, as well as leveraging synergies and complementarities with other energy solutions such as renewable energy, energy storage, smart grids and digitalization can increase production, distribution and consumption of hydrogen from various sources and sectors. Lastly, promoting innovation and collaboration across different industries, applications and regions can create new value chains, business models and partnerships.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are the best practices for using hydrogen fuel cells to power industrial machinery?

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1 How hydrogen fuel cells work

2 Types of hydrogen fuel cells

3 Benefits of hydrogen fuel cells for industrial machinery

4 Challenges and risks of hydrogen fuel cells for industrial machinery

5 Best practices for using hydrogen fuel cells for industrial machinery

6 Future trends and opportunities of hydrogen fuel cells for industrial machinery

7 Here’s what else to consider

Mechanical Engineering

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What are the best practices for using hydrogen fuel cells to power industrial machinery?

1

2

3

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5

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1 How hydrogen fuel cells work

2 Types of hydrogen fuel cells

3 Benefits of hydrogen fuel cells for industrial machinery

4 Challenges and risks of hydrogen fuel cells for industrial machinery

5 Best practices for using hydrogen fuel cells for industrial machinery

6 Future trends and opportunities of hydrogen fuel cells for industrial machinery

7 Here’s what else to consider

Mechanical Engineering

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