Hydrogen (H₂) Filling System for Bus Fleet
Industry: Public Transportation
Location: USA
Timeline: Several months
Client: A leader in the production of hydrogen-powered buses
Fluitron designed, supplied, and installed a state-of-the-art hydrogen (H₂) filling system for two hydrogen powered buses. The system was designed and engineered to deliver 30kg of hydrogen per bus in a back-to-back filling process, ensuring minimal downtime and maximum operational efficiency for the operator.
The project also included the integration of Fluitron’s proprietary technologies, such as an in-house-developed hydrogen dispenser and an advanced hydrogen inventory management system, which enhanced reliability and control.
- 30 kg of hydrogen delivered per bus.
- Back-to-back filling capability.
- 2 compressors to handle boil-off and post-refuel replenishment.
- Real-time telemetry and inventory management for continuous up time.
- Proprietary dispenser designed for precise, safe, and efficient fueling
The project encompassed the design, installation, and commissioning of a hydrogen filling station capable of reliably meeting the fueling needs of two hydrogen-powered buses. Fluitron worked in close collaboration with major industrial gas supplier, Linde, to ensure the H2 filling station met the specific fueling needs of the two buses.
- Rapid and efficient refueling of buses to minimize operational downtime.
- Ensuring continuous uptime through real-time monitoring and telemetry.
- Integration of the new system into the existing infrastructure
- Scalability to meet future fleet expansion targets.
Innovative Technologies for Seamless Hydrogen Refueling
The hydrogen filling station is designed to be both efficient and reliable, incorporating several key technologies:
- Ambient Temperature Vaporizer - This technology allows for the vaporization of liquid hydrogen at ambient temperatures, optimizing energy consumption and ensuring the hydrogen is converted into gas at the required pressure.
- Y7 Diaphragm Compressors - Fluitron’s diaphragm compressors are central to the system’s efficiency. One compressor is dedicated to handling the boil-off from the hydrogen storage tank, while the second compressor boosts the system’s capacity during refueling. This two-stage approach enhances overall operational flexibility.
- Cascade Storage System - The cascade design ensures that hydrogen is stored at multiple pressure levels, providing the necessary pressure during filling and reducing the time spent on refueling.
- Telematics and Monitoring - By incorporating telematics, the system offers proactive monitoring of the fill process, allowing the operator to track hydrogen usage, refuel progress, and any potential system issues in real-time. Alerts and diagnostic data are sent directly to the team to address maintenance needs quickly.
- In-House Hydrogen Dispenser - The dispenser plays a critical role in delivering precise hydrogen fills to the buses. It integrates seamlessly with the rest of the fueling infrastructure, ensuring a safe, efficient, and fast refueling process.
- Hydrogen Inventory Management System - The proprietary inventory management system ensures that hydrogen is tracked from delivery to dispense, providing a full view of inventory levels, refill schedules, and overall hydrogen usage. This system allows operators to make data-driven decisions, reducing operational inefficiencies and ensuring the filling station always has the necessary hydrogen available.
A Scalable, Sustainable, Reliable Hydrogen Fueling Solution for Public Transit
The project successfully delivered an optimized hydrogen filling system, using Fluitron’s in-house developed hydrogen dispenser and proprietary inventory management system, to meet New Flyer’s operational and sustainability goals.
Key outcomes included:
- Operational Efficiency: Rapid back-to-back fills with minimal downtime.
- Continuous Uptime: Dual compressors and telemetry ensured uninterrupted operation.
- Future-Proof Design: Scalable infrastructure to support fleet growth.
- Improved Sustainability: Enabled zero-emission hydrogen-powered bus operations.
