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Atyrau Oil & Gas

Pumps and Valves for Green Hydrogen Power

Along with the metal industry, the chemical industry consumes the most energy – and the majority of it still comes from fossil fuels. However, this will soon change when at least part of the supply will be replaced by green hydrogen. Pumps and valves will play a decisive role in making this low-carbon switch.

Decarbonisation drive in industry

Green hydrogen, i.e. hydrogen produced in a climate-neutral manner, is becoming increasingly important as an energy source for industry. Not only can this hydrogen be used to power vehicles and for storing renewable energy, it can also be used to defossilise material value chains. In refineries, for example, the “grey” hydrogen which is produced from the steam reforming of natural gas currently used to desulphurise the pre-products of petrol and diesel could gradually be replaced by its green counterpart.

In the steel industry, green hydrogen is already being used for the direct reduction of iron ore as an alternative to the furnace process with high greenhouse gas emissions, albeit so far only in pilot projects.

The prerequisite for such a switch is the development of an efficient and at the same time economical hydrogen economy – including the necessary infrastructure for the production, import, transport, storage and conversion of the gas. That’s the theory at least. In reality, many more details need to be considered when implementing such strategies.

Kazakhstan, at the government level, supports such an important stage of the energy transition and related projects in order to increase the competitiveness and sustainability of local industry enterprises in the world market.

Pumps and valves of today for the green industry of the future

As a technology company with engineering expertise in the fields of process engineering, petrochemicals and renewable energies, KSB has been active in the area of hydrogen technology for many years. Both its valve and pump portfolios already comprise many products that can be used in all stages of the hydrogen value chain. KSB can also draw on numerous reference projects and extensive experience gained with KSB products in known or piloted hydrogen production technologies, covering both blue and green hydrogen.

Hydrogen applications place high demands on the components used. A particular challenge when implementing hydrogen projects is that the material requirements for the components used vary greatly and differ from the ones for conventional applications. 

As a supplier with decades of experience, KSB has the advantage of already being very familiar with the processes used in applications in the chemical industry. Especially regarding conversion processes (e.g. the production of ammonia) and grey hydrogen production processes based on fossil fuels (SMR, ATR, CCS), KSB is able to offer its complex engineering solutions for green energy and industry.

One of the biggest challenges on the path to a sustainable hydrogen economy is the size of future systems. At the moment, electrolysers are built on a modular basis using small subsystems. However, the question is whether modular container solutions or integrated large-scale systems/interconnected systems will prevail in future or perhaps there will be even both.

This would obviously have a direct effect on the choice of pumps and valves used. While the flow rates with container solutions are around 10 m³/h, large-scale systems (according to studies) could easily reach 800 m³/h. Likewise, the operating pressure may range from 6 to 40 bar.

Larger modular systems may also have higher control requirements for optimum interaction of components. KSB offers both variable speed pumps and control valves for such applications. In large-scale integrated systems, the reliability of individual components could play an even greater role. Here, KSB already offers monitoring systems for supervision of operation and early detection of malfunctions.

Pic.1 Hydrogen electrolyser as a compact container solution: the flow rate here is around 10 m³/h

As a supplier of pumps and valves, KSB offers a broad range of products to cover a wide field of applications as well as its expertise in systems engineering, operating modes, materials and energy efficiency.

KSB’s products cover all of the main green hydrogen production technologies, including various solutions for electrolysis – from alkaline electrolysis (AEL) and proton exchange membrane electrolysis (PEM) to promising future technologies such as anion exchange membrane electrolysis (AEM) and high-temperature electrolysis (HTEL).

Products employed to make the processes safer are seal-less pumps and diaphragm valves, such as the SISTO-16 or SISTO-20 type series, or butterfly valves, such as ISORIA or the KE type series, that are made of corrosion-resistant material or coated accordingly. Swing check valves from the SISTO-RSK or SISTO-RSKS type series with elastomer linings or ECTFE coatings, which require extremely short stabilisation distances and have no rotating components, further increase the reliability and continuous operation of the systems.

Pic.2: SISTO-20 diaphragm valve - the stem and all internal operating elements are not in contact with the fluid

SISTO diaphragm valves only have two components that come into contact with the fluid handled: the valve body and the diaphragm itself.

The diaphragm provides absolutely tight shut-off as well as hermetic sealing to atmosphere. SISTO’s unique sealing system features a diaphragm enclosed in the body and supported by a metal spiral in all valve positions. Depending on the application, diaphragm valves can be selected with optimally suited body materials, linings and coatings. Choosing the right diaphragm is the key! In addition to elastomer diaphragms, KSB offers diaphragms made of TFM with an additional PVDF barrier foil as well as EPDM backing diaphragms.

Valves needed for cryogenic applications, such as the subsequent transport, are covered by the DANAÏS valve type series in the KSB portfolio. Furthermore, the fluidics specialists at KSB have accumulated experience with valves for liquid hydrogen (-253 °C) from optimising the Ariane rocket in test facilities.

Magnochem seal-less pumps with magnetic drive

Pic.3 Magnochem

Among the pumps tried and tested in alkaline electrolysis is the Magnochem horizontal volute casing pump with magnetic drive, available in close-coupled design or back pull-out design. This seal-less pump has been used for many years whenever toxic, explosive or valuable fluids have to be pumped in industry. It is the ideal match for hydrogen technology as well.

Magnochem range

With its magnetic drive, the standardised chemical pump is hermetically sealed, averting the risk of leakage. This plays a major role in alkaline electrolysis, where caustic potash is pumped that crystallises in contact with the atmosphere and can be harmful to health. Thanks to its close-coupled design, the pump set is ideal for tight installation spaces.

The patented containment shrouds are extremely resistant to corrosion and do not produce eddy currents when them magnetic field passes through it. Undesirable heat losses which would reduce output and compromise pump efficiency are thus eliminated.

Pic.4: MagnoProtect

In addition, to improve safety and expand the application range of Magnochem pumps KSB introduces the newest patented MagnoProtect containment shroud which combines the very latest additive manufacturing technology and innovative safety provided by two static leakage barriers. This technology is compatible with all existing Magnochem types enabling them to meet the requirements of industrial safety and operate at temperatures up to 400 °C and pressures up to 40 bar.

Compliant with ISO 5199, the pump meets the toughest of quality standards and is available in a multitude of materials. With its broad range of hydraulic sizes and magnetic drives, Magnochem offers a large number of technically feasible variants, making it a good match for the most diverse of tasks in hydrogen production, and the user receives a pump with a maximum of safety, reliability and economic efficiency.

Pic.5: Movitec

Another pump suitable for hydrogen production is the Movitec multi-stage, vertical high-pressure centrifugal pump. It is used for water treatment and pressure generation, for instance. It is designed for up to 40 bar and is very flexible with the number of stages and the option of speed control. Movitec’s compact design is a perfect match for installation in tight spaces, like in container solutions or modules. Even at low flow rates it can generate high pressures.

The Movitec high-pressure in-line pump is available in a wide range of variants – always perfectly suited to the specific application.

Hydrogen technology involves more than just hydrogen production. Another key process is the sufficient supply of cooling water. 

Рис 6: Etaline

Pumps from the Etabloc/Etaline type series and valves from the ISORIA and SISTO-20 series are perfect for cooling heat exchangers. Thanks to their variable speed drive, the pumps impress with maximum energy efficiency. Their compact design makes them flexible and well-suited for installation in container solutions.

Known for more than a century, alkaline electrolysis is among the most highly developed electrolysis technologies. PEM electrolysis is a much more recent technology that offers the benefits of a compact system design and high flexibility at changing loads. Compared to alkaline electrolysis, the process offers a lot of potential for future technical developments and cost savings. It also has the major advantage that it does not require the use of any risky chemicals, except for the toxic electrolyte. The application of pumps and valves are similar to those of alkaline electrolysis. The new technology promises to deliver particular benefits once hydrogen production from renewable energy sources becomes widespread in future.Already today, diaphragm valves and butterfly valves as well as various pumps made by KSB are used in pilot systems.

KSB is also well equipped for the tasks of future technologies, such as anion exchange membrane electrolysis (AEM) or high-temperature electrolysis (HTEL).

The experts see a particular challenge in the high temperatures that place demanding requirements on materials. KSB is involved in several research projects to test new alloys for valves and their advantages when the components are exposed to such conditions.

Regardless which electrolysis process will be used in the future and what system size will prove more suitable, KSB’s portfolio covers all the diversity of requirements. And thanks to decades of experience, KSB offers pumps and valves that can be fine-tuned to every process to achieve the best efficiency as well as maximum safety and reliability.

https://www.ksb.com/en-kz