Project Case Study
Hydrogen Separation Plant
Hydrogen Separation Technology
Compact System
Fully automated skid‑mounted (3.9 m × 4.8 m × 3.8 m) integrates cyclonic system and adsorbent technology
Certified & High Capacity
CE/UKCA & ATEX certified; processes 550 Nm³/hr at 80 Pa for safe and efficient gas management.
Delivered in 28 Weeks
Strict timeline met by collaborating with suppliers to tailor equipment and integrate with existing infrastructure.
Overview
Client (UK) engaged Kapwell to conduct a detailed evaluation study for replacing an existing underground hydrogen scrubbing plant serving a UPS battery room ventilation system. The objective was to identify a compact, efficient, and low-maintenance hydrogen removal solution suitable for a fully enclosed, recirculating ventilation environment.
The existing system required replacement due to operational limitations and the need for improved safety, performance, and maintainability.
Key Challenges
- Underground installation with limited space constraints
- Fully enclosed ventilation system with no discharge to atmosphere
- Hydrogen accumulation risk from VRLA battery operation
- Requirement to maintain hydrogen levels below explosive limits
- Need for compact footprint and minimal maintenance solution
Solution
Kapwell proposed a compact Hydrogen Scrubber Package integrated with a compressor system designed specifically for underground and confined installations. The system operates intermittently based on hydrogen concentration levels, ensuring energy-efficient operation.
Key Features:
- Modular hydrogen scrubber and compressor package
- Automatic operation triggered at 1% LEL hydrogen concentration
- Integrated water removal system with drain pump
- Compact footprint optimized for plantroom constraints
- Manual gas testing facility at outlet
- Fully integrated control panel with BMS compatibility
Key
Features
Certified High-Capacity Design
The system is CE/UKCA and ATEX certified, suitable for use in hazardous environments. It is capable of processing approximately 550 Nm³/hr of hydrogen gas with minimal pressure drop (about 80 Pa), ensuring safe and efficient gas handling. This certification and capacity demonstrate Kapwell’s commitment to meeting international standards and performance criteria.
Integrated Cyclone & Adsorbent Technology
The skid features a hybrid separation setup – a high-efficiency cyclone separator removes bulk liquids/solids, while a downstream adsorbent reactor beds out remaining impurities. This integrated approach achieves a high purity hydrogen output that single-method systems cannot, highlighting Kapwell’s innovative engineering.
Compact & Automated Skid
Designed with a small footprint and full automation, the entire system is mounted on a single skid. This compact design simplifies transportation and installation, and the automation ensures continuous operation with minimal operator intervention. All components were arranged to optimize space without compromising maintainability.
Challenges & Innovation
One key challenge was achieving high-purity separation under a strict timeline. The client required a rapid delivery and installation, as well as integration with their operational plant. Kapwell addressed this by collaborating closely with suppliers and customizing the equipment design for quick hook-up to the existing setup. Another technical challenge was handling hydrogen a small, highly flammable molecule – safely and effectively. Kapwell’s innovative hybrid solution (cyclonic + adsorbent) ensured that even trace contaminants were removed, demonstrating an innovative approach to hydrogen gas treatment. The combination of separation technologies in a single compact unit was a novel solution that met performance goals while maintaining safety standards.
Client Benefit
Safe & Compliant Hydrogen Management
The client can now handle hydrogen gas with confidence. The ATEX-certified system guarantees explosion safety, and the removal of impurities down to low levels means compliance with safety and quality specifications for hydrogen.
Improved Process Efficiency
By delivering 550 Nm³/hr of clean hydrogen with very low pressure drop, the system ensures efficient use of compression energy and maximized hydrogen recovery. This improves overall process performance and throughput.
On-Time Delivery & Integration
The project was delivered within 28 weeks from order, meeting the strict timeline required by the client. On-time delivery allowed the client to implement the solution without project delays. The seamless integration of the skid into their facility minimized downtime and avoided costly modifications.
Enhanced Reliability
The fully automated, skid-based design offers high reliability and ease of operation. The client benefits from reduced maintenance (thanks to proven separation hardware) and reliable performance in managing hydrogen, which is critical for continuous operations.
Timeline
Delivered in 28 weeks. Kapwell met a strict project timeline by expediting design and procurement, and by working in parallel with the client’s site preparations. The on-schedule delivery enabled prompt commissioning and start-up of the hydrogen separation system.