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Custom designed reciprocating H2 Compressors 20- 12000 Nm/h up to 22 Mpa. Specifically designed to serve various applications such as: refinery recycle hydrogen, pre-compression for hydrogen fuel stations, chemical hydrogenation and storage of energy throughout the hydrogen value chain.
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Your hydrogen compression system has to deal with a gas that aggressively attacks its containment materials, seeps through microscopic leaks unlocatable by normal seals, and ignites in an air flammability range of 4-75%. Consumer-grade industrial gas compressors haven’t succeeded in hydrogen service because they weren’t built for these circumstances. A hydrogen booster compressor—a high pressure reciprocating compressor designed to compress hydrogen gas from a low inlet pressure to a high discharge pressure—pre-empts all of these blowing conditions before they can occur.
The first, and largest, is (ironically) hydrogen embrittlement: atomic H2 migrates through the wall of a metal grain or apartment under pressure, cycling temperature and pressure, and nucleating microcracks that (with persistence) lead to ultimate failure. Steel garments that have to ole to show lengthy record of no problems in N2 or NG gloves turn seal-hard within a few months under H2 hands.
Second is molecular leakage–with a (kinetic) molecule diameter of just 2.89 (and 3.00) angstroms, H2 can sneak through clearances that retain methane and higher molecular weight gases.
Third is contamination—many of the downstream H2 applications-LHV fuel cell cars to catalytic H2 blowing reactors to chemical-grade processing will always require oil-free or ultra-zero-oil compression.
Fourth, (to the extent that one can pressurize) a 20 to 22 MPa discharge from an inlet that can be as low as 0.02 MPa (electrolysis pressures sometimes are found below 0.10 MPa) requires multi-stage compression with millers of degrees of intercooling-a scientific art form that is same(s) to the accomplishment.
This is achieved using reciprocating piston technology proven over 11+ years in multiple applications, using hydrogen rated all-welded construction materials, specifically 316 stainless steels with a minimum of 10% Nickel, each mill certificate traceable back to the original heat number. The double mechanical-electronic compressor protection system measures discharge temperature and pressure, oil flow and vibration in real time and trip out (shut down) in milliseconds should the compressor operate outside pre-selected limits. The compressor is all air cooled with no requirement for cooling water infrastructure and is therefore quick, simple and cost effective to install and maintain onsite.
All wear parts (piston rings, packing sets, inlet- and valve plates) are compatible across the product family so replacement items are available within 5-10 business days ex-stock worldwide.
Hydrogen embrittlement is observed when monatomic hydrogen diffuses through the metal lattice and re-combines at grain boundaries, forming “a build-up of internal pressure and causing the grain boundaries to crack intergranularly”. This becomes a concern at above 200C, and at increased partial pressures of H 2. in the compressor cylinders and valve components, this leads to brittle fracture during normal pressure cycling.
Pangeng’s preventive approach: all parts that contain pressure takeoff made from 316L stainless steel (UNS S31603). Confirmed %Ni greater than 10%, balls and seat ring half-HRC < 22. After machining, passivate all critical parts in solution at 1040-1080C then normalize quench to prevent carbide precipitate formation from further complicating traps made in time of manufacturing.
Check all surfaces for positive material identification (PMI) using a hand-held X-ray fluorescence device before installation. Referenced procedure against ASME BPVC Section VIII, Division 1 specification for hydrogen.
Our three product families deliver different solutions for different segments of the hydrogen value chain. When your application is new hydrogen compression for refinery makeup gas or recycle hydrogen boosting for hydrocracking loops—or high-pressure gas compression for fuel station dispensing at 700 bar—we can start from a standard platform—and then design every parameter to fit your process.
ZW series: new hydrogen from steam methane reformers, pressure swing adsorption units, or electrolysis. Our ZW-series compressors are designed to take in hydrogen at relatively moderate inlet pressures and boost it to process-feed conditions. Typical volume flows are 350 to 740 Nm/h, and the package is designed to be space-saving and modular.
Variations in design are available to suit new hydrogen generation from these sources for use in chemical plants, or other processes calling for mid-tier hydrogen volume flow rates.
ZT series: new or recycle hydrogen for downstream processing. Core components of refinery hydroprocessing units (hydrotreaters, hydrocrackers, isomerization reactors) rely on a continual flow of recycle hydrogen to maintain catalyst activity and ensure adequate conversion rates. Our ZT series is the durable solution to the persistent demand of refinery 24/7 operation: typical flow rates are 700 to 12,000 Nm/h, and inlet pressures are as low as 0.02 MPa (for low-pressure flash gas removal), with discharge pressures reaching 10.0 MPa.
High-pressure gas compression to dispensing stations at 350 or 700 bar, energy storage compression for tube trailers at 200 bar or greater, and pipeline transport require a high-pressure platform capable of reaching up to 22 MPa. Permutations of compression stage count, cooling duty, and safety apparatus can be incorporated to meet your exact needs. Plug-and-play design reduces installation time on site to a matter of days.
| Series | Application | Flow Rate (Nm³/h) | Inlet Pressure (MPa) | Discharge Pressure (MPa) | Stages |
|---|---|---|---|---|---|
| ZW-0.6/(0.6–1.0)–3.5 | New H2 Feed | 350–740 | 0.6–1.0 | 3.0–3.5 | 2 |
| DW-0.8/0.02–1.2 | Low-P Recycle H2 | 700–2,500 | 0.02–0.5 | 1.2–3.0 | 2–3 |
| DW-3.0/1.0–5.0 | Medium-P Recycle H2 | 1,500–6,000 | 1.0–2.5 | 3.0–5.0 | 2 |
| DW-6.0/2.0–10.0 | High-P Recycle H2 | 3,000–12,000 | 2.0–4.0 | 5.0–10.0 | 2–3 |
| Custom HP Platform | Fuel Station / Storage | 20–1,000 | 0.5–4.0 | 10.0–22.0 | 3–5 |
Which hydrogen compressor should I choose? An initial step should be to identify the process conditions where our solution should focus. The chart below provides a visualization of four key sectors of application mapped to recommended series, typical operating points, and selection symbols.
| Application Sector | Recommended Series | Typical Pressure (MPa) | Typical Flow (Nm³/h) | Key Selection Criteria |
|---|---|---|---|---|
| Refinery Hydroprocessing | DW Series | 1.2–10.0 | 700–12,000 | 24/7 reliability, API 618 compliance, long service intervals |
| Hydrogen Refueling Stations | Custom HP | 35.0–45.0 (350 bar) / 70.0–90.0 (700 bar cascade) | 20–500 | ISO 14687 purity, small footprint, ATEX zone classification |
| Chemical Processing | ZW / DW Series | 3.0–5.0 | 350–6,000 | Oil-free options, gas purity, process integration |
| Energy Storage & Transport | Custom HP | 20.0–22.0 | 50–1,000 | Tube trailer filling, post-electrolysis compression, modular skids |
How to select a compression technology for your hydrogen process requires parallel comparison of compression technologies against several criteria: pressure capability, volume throughput, system simplification and trading for purity, maintenance intensity, and total cost of ownership. The table below compares parameters for four existing technology types, and consolidates specification experience from existing refinery, chemical, and clean energy projects.
Reciprocating piston compression-compression technology employed by all Pangeng hydrogen boosteras- offers the widest breadth of operating range: inlet pressures from 0.02 MPa to 22 MPa of discharge pressure, flow rates from 20 to 12,000 Nm/h. For applications that might involve small-flow electrolysis or subsequent compression processes, membranes precisely zero impurities emerge as a distinct technology option. At the high end, centrifugal compression technology performs best at flow rates greater than 1,000 Nm/h but, of course, supports only a limited compression ratio.
| Parameter | Pangeng Reciprocating Booster | Centrifugal | Diaphragm | Electrochemical |
|---|---|---|---|---|
| Pressure Range (MPa) | 0.02–22 | 0.5–100 | 0.1–1000 | 0.1–100 |
| Flow Rate (Nm³/h) | 20–12,000 | 1,000–100,000+ | 1–500 | 0.5–50 |
| Gas Purity Impact | Oil-free / oil-lubricated options | Oil-free (dynamic seals) | Zero contamination | Oil-free (electrochemical) |
| Compression Ratio per Stage | 2:1–4:1 | 1.2:1–2:1 | 3:1–10:1 | N/A (continuous) |
| Maintenance Interval (hrs) | 4,000–12,000 | 16,000–24,000 | 2,000–6,000 | 8,000–20,000 |
| Customization Flexibility | Full (stages, materials, skid) | Limited | Moderate | Limited |
| Footprint (relative) | Medium | Large | Small | Small |
| Capital Cost (relative) | $$ | $$$ | $$$$ | $$$$$ |
In the majority of industrial hydrogen uses where there is a need for significant throughput and high discharge pressure, reciprocating piston technology provides the optimal solution in terms of performance, dependability, and total ownership cost. If your application is outside of the reciprocating envelope-an application requiring either very high flows less than 12,000 Nm/hr or very low flows less than 20 Nm/hr with very high purity requirements-pring is happy to consider other technologies.
Equipment is 25-40% of overall lifecycle cost, with energy usage, wear parts and scheduled maintenance making up the rest. Pangeng’s modular built along with standardized wear parts then helps to reduce any long term ownership costs through minimizing special skills required at service intervals and minimum required of proprietary parts.
We design hydrogen booster compressors to meet exact process conditions-not a generic duty point. Here are 5 actual application cases in which our compressor solutions provided value for money. We show what the process parameters are for our engineering department to perform technical proposals for the compressor solution.
Refinery hydroprocessing utilizes both recycled hydrogen (that of the separator at the reactor at a lower pressure) as well as makeup fresh hydrogen. Our DW-series recycle H2 compressors re-compress separator gas from about 1.5-3.0 MPa back to the reactor inlet pressures (ca 5.0-10.0 MPa) to preserve the high partial pressure of H2 for catalyst activity. ZW-series fresh H2 compressors provide the makeup H2 at from ca. 3.0 to about 3.5 MPa from the hydrogen plant.
Though not so popular we normally engineer both units for dual purpose they run on the same machine architecture, same control loops, and keep the maintenance schedules in sync.
Refuelling of a hydrogen fuel cell vehicle involves compression of hydrogen from the electrolyzer or pipeline supply pressure (around 0.5-3.0 MPa) up to cascade storage pressure, i.e. 45 MPa (for 350-bar dispensers) or 90 MPa (for 700-bar dispensers). Our high-pressure platform compresses H2 in 4-5 stages with intercooling after each stage, while for 700-bar stations we have integrated downstream pre-cooling to -40C to comply with fill protocols specified by SAE J2601. Skid-mounted packages are supplied complete with PLC controls, safety interlocks, gas detection equipment and other facilities for quick-field installation.
This is what makes our high-pressure system the ideal equipment solution for hydrogen refueling stations.
Fine chemical, pharmaceutical and edible oil processing often use hydrogenation reactions for processing, demanding hydrogen at exact pressures and purity specifications. These compressors deliver processed hydrogen at conditions suitable for feeding to reactors (approx 3.0-5.0 MPa) from PSA or electrolyser sources. Oil free piston arrangements avoid carry over of lubricants to catalytic processes.
Variable speed drives or suction valve unloading allow turndown to 50% of flow without recycling for effective matching of hydrogen supply to batch or continuous reactor demand curves.
Upon generation green hydrogen, made by alkaline or PEM electrolysers, is at a relatively low pressure-typically 0.1-3.0 MPa. It must be compressed for storage in tube trailers at 200 bar (20 MPa) or more for transportation to end use facilities. Pangeng compressors provide the real-time, cost-effective compression from low to high pressures in 3-4 efficient compression stages with air cooled intercoolers.
We can offer modular, skid mounted packages installed adjacent to solar or wind farms, with additional units to parallel as hydrogen production capacity increases.
Moving hydrogen from generation location to the end user requires increasing pressure for pipeline injection or tube trailer loading. Pipeline booster stations raise the hydrogen pressure from 2.0-4.0 MPa to 6.0-10.0 MPa overcoming transmission frictions losses over 50-200+ km. Tube trailer filling compressors must steadily support a broad pressure range as trailer banks fill from residual 0.5 MPa to full 20-22 MPa. Our hydraulic-actuated capacity control delivers a steady throughput over this changing backpressure curve ensuring complete fills within desired cycle times. These compression systems form essential infrastructure of the growing hydrogen economy linking renewable green hydrogen generation on sun and wind powered sites to our industries.
Every Pangeng hydrogen booster compressor is designed and built to adhere to a certified quality system, with pressure retaining components constructed to date ASTM, API, or ASME code. We understand project engineers require paperwork compliance-not just verbal assurances. Below is an overview of the quality standards governing our hydrogen compressor manufacturing, testing, and sourcing.
Quality Management System
Pressure Vessel Design & Fabrication
Reciprocating Compressor Design
Hydrogen Fuel Purity Standard
Explosion Protection Certification
European Market Conformity
Trucking is only part of your story with Pangeng. In addition to our delivery assurance: live remote troubleshooting & operator consultation via video conferencing, attendance at compressor start-up on your site by our service technicians (available around the world), standard low-wear parts availabilities from our Bengbu, Anhui warehousing that dispatch within 5-10 working days normally, and annual maintenance scope agreements with defined time of response. We keep the tech file of every compressor we supplied you for spare parts arrangement and service intervention refer to your built optimization.
Engineering calculators and selection guides designed for high-pressure hydrogen applications.
Identify the optimal booster compressor model based on intake pressure, discharge requirements, and flow rate.
Access ToolCalculate compression ratios, discharge temperatures, and optimize multi-stage configurations.
Access ToolEvaluate the Total Cost of Ownership including CAPEX, OPEX, and projected maintenance cycles.
Access Tool