COMPRESSORS

HYDROGEN
COMPRESSION -
Prospects & Challenges
Reciprocating and centrifugal compressors are viable options for
hydrogen compression with enhanced and adapted sealing methods,
alternative valve selections, and additional staging.
BY KLAUS BRUN, TIMOTHY C. ALLISON, MARYBETH MCBAIN,
STEPHEN ROSS, AND EUGENE L. BROERMAN III

he use of hydrogen as a decar- renewable power that can be stored at boosting, and use at gas-fired power
bonized fuel and for long-term high pressures and transported via plants, as well as vehicle/aircraft fueling
energy storage involves various pressurized pipelines, typically up to stations. Providing hydrogen-compres-
types of hydrogen-based solutions. These 1,440 psi. However, compressing hydro- sion solutions for such a broad range of
solutions must be capable of delivering gen is power-intensive due to its energy target applications challenges the
clean power via hydrogen fuel for the density being very low on a volumetric technologies that are currently available,
production, transport, storage, and use of basis. Compared to natural gas pipelines, giving rise to critical questions on how to
hydrogen, with lower overall emissions for equivalent energy volumes, hydrogen adapt compression technologies to meet
than alternative decarbonized ener- compression will likely require 5 - 6 times the wide variety of needs.
gy-storage technologies. Thermochemical the power (FIGURE 1)1. This makes In the short term, generating hydro-
technologies, including hydrogen as efficiency in design and the overall gen from fossil fuels with carbon capture
energy storage, provide the only long footprint requirement key aspects when and sequestration (CCS) offers lower costs
durations required for seasonal and daily evaluating various and production closer to the point of use.
fluctuations in renewables. compressor technologies. This pathway to power production from
In this value chain, hydrogen compres- hydrogen-blended gas will likely require
THE HYDROGEN VALUE CHAIN sion will be needed for a range of applica- less pipeline compression and possibly
Hydrogen is used in a power-to-gas (P2G) tions, including pipeline transportation, lower delivery pressures. In the case of
approach as energy storage for excess production, storage, transport, fuel gas-fired power plants, volume flows will

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COMPRESSORS

hydrogen with natural gas, appreciable

FIGURE 1. Comparison of Energy-Storage Forms – Discharge Time vs. Rated Power concentrations of hydrogen will be needed
to significantly decrease carbon emis-
sions. The Btu/min flow to the turbine
Response and Total Discharge Time Window at Rated Power

T&D Grid Support

UPS Power Quality Load Shufting Bulk Power Mgt. must remain constant for the 50 MW
combustion gas turbine system shown in
Months

Thermochemical FIGURE 2 for a blended fuel stream, which

means that the natural gas flow falls off
Days

Pumped Heat Liquid Air non-linearly with increasing hydrogen

Compressed Air content. Operators will need to blend
more than 50% hydrogen to start making
Hours

Flow Batteries
an appreciable difference in carbon
emissions, and many gas turbine manu-
facturers are already investigating means
Minutes

Solid-State
Batteries Pumped Hydro
Gravity-Based of operating at 100% hydrogen fuel.
The challenge with hydrogen compres-
Seconds

Flywheels
sion is in the large flow rates and the
Supercapacitors variety of pressure ratios required for the
1kW 10kW 100kW 1MW 10MW 100MW 1 GW+ decarbonized energy market compared to
compressors used in refinery applica-
tions. The higher compression ratios
be scaled to the size of the existing gas recompression in the pipeline at ratios of required for the transportation/power
turbine and natural gas combined-cycle 1.2 - 1.3. Compression ratios for storage sector will require design adaptations for
(NGCC) power plants, so compression applications will be much higher, up to both reciprocating and centrifugal
technology will need to match the 10.0. Fuel-line-booster compression may compressors, including enhanced sealing
power-plant delivery flow rates. For the require ratios of 2.5 - 3.5 and be most methods, alternative valve selections, and
transportation sector, smaller modular relevant to hydrogen production at the additional staging.
compressors will be required for vehicle point of use, i.e., the gas turbine FIGURE 3 displays some of these
fueling stations. The CO₂ compression power plant. requirements relative to the head/flow
requirements for this pathway will be Due to hydrogen’s low energy volume capabilities of existing reciprocating and
significant and require additional CO₂ density compared to pipeline-quality barrel-style multistage centrifugal
pipelines and compression.2 natural gas volume density, in blending compressors for a range of hydrogen flow

COMPRESSORS FIGURE 2. Calculated Equivalent Fuel Volumes for LM2500 Combustion Gas Turbine
While different types of compressors are Producing 50 MW at ISO Conditions
used in industrial applications and vehicle
refueling stations, the larger power Blending Natural Gas and Hydrogen by Volume Flow
30000
applications for storage and pipelines
— Volume of H 2
realistically limits the selection to 25000 — Volume of Natural Gas
reciprocating and centrifugal compres- — Volume of Mixed Gas
20000
sors. Both have precedence in this area as
well as relevant designs, with high 15000
reliability in refinery/plastic production
processes, albeit at lower ratios and lower 10000
overall discharge pressures.
5000
Compression requirements are largely
similar from production to transport, 0
0 10 20 30 40 50 60 70 80 90 100
requiring booster units to compress into Percent of Hydrogen Gas (%)
the pipeline at ratios of 2.5 - 3.0 and

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COMPRESSORS

above, and compression design variability

FIGURE 3. Comparison of Hydrogen Compressor Requirements vs. Capabilities for
for a range of pressure ratios. The com-
Pipelines Transporting 6-25 GW (500-2150 MMSCFD)
pounded effect of low energy density by
volume and high head due to its high
2500 –­ specific heat makes hydrogen compression
Reciprocating
Compressor H 2 Production to Pipeline challenging and power-intensive.
Capabilities PR ≈ 3.4-5.0
2000 –­ Managing the higher head for the larger
Polytropic Head, kJ/kg

pressure ratios associated with hydrogen

1500 –­ production and pipeline boosters is a key
design parameter. Intercooling between
H 2 Pipeline Station
1000 –­ PR ≈ 1.2-1.4 stages is crucial to protecting internal
components and keeping power consump-
Natural Gas Pipeline Station
500 –­ PR < 1.3 tion low but is complicated by the need to
maintain a semi-compact footprint for
Multistage Centrifugal
0 –­ Compressor Capabilities reciprocating compressor pulsation
–­

–­

–­

–­

–­

–­

ၡ
bottles, lube oil systems, and intercoolers
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
and their associated piping.5
x10 5
Volume Flow, m 3 /hr TABLE 1 compares the advantages and
disadvantages of the various compression
options for hydrogen.
conditions corresponding to transported STORAGE PRESSURES AND The various hydrogen technologies that
fuel energy content from 6-25 GW TEMPERATURES are currently available each has distinct
(500-2,150 MMSCFD natural gas), which In addition, to harness excess renewable applications where the compressor choice
correspond to a range of pipeline sizes power in P2G applications, hydrogen may be more apparent. However, in many
analyzed in Allison, et al., 2021.3 compressors for storage will need to likely applications, an overlap of competing
The two lower-left solid rectangles deliver at 3,000 psi and above (FIGURE 4)4 technologies can be expected. It is in the
show a comparison of natural gas versus for injection at the top end of the reservoir. best interest of operators to compare
hydrogen compressors for transport at Initial boosters to take hydrogen from these technologies for each application
pipeline stations, where compression production pressure to pipeline pressures space and to evaluate details of the
requirements increase for hydrogen due (atmospheric to 100 psi) will require compressor offerings such as overall
to the lower volumetric energy density of hydrogen compressors capable of a high physical size, accessibility for operations,
hydrogen and the thermodynamic number of multiple stages due to significant capex/opex cost, manufacturer experi-
properties of hydrogen that require more head requirements. Hydrogen compressors ence, and durability of each technology.
power to achieve the same pressure ratio will need to move to designs at higher rated Operators should also consider how
when compared with natural gas. The motor and engine drivers, likely 10 MW and the technology accommodates the
upper-right solid rectangle illustrates
compression requirements for boosting
FIGURE 4. Hydrogen Storage Pressures and Temperatures
hydrogen from its production pressures of
20 - 25 bar to pipeline pressures of 85 - 100
160 ­–  H
ydrogen production
bar. The dashed rectangles show the technologies
capabilities of existing technologies for 120 ­–  Transmission pipes
hydrogen compressors. In general,  Steel distribution pipes
Temperature (°C)

80 ­–  Plastic distribution pipes

reciprocating compressors may struggle
Transmission outlet
 
with meeting flow requirements for 40 ­– pressure vessels
hydrogen compression, whereas centrifu- A bove ground storage
 
0 ­– tanks
­–

­–

­–

­–

­–

­–

gal compressors will struggle to meet the 10 20 30 40 50 60 70 80

 Vehicle storage tanks
head requirement for hydrogen compres- -40 ­–  Salt cavern storage
sion in a single unit. Pressure (MPa)  Depleted gas field storage

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COMPRESSORS

TABLE 1: Comparison of “Mainline Flow” Compressor Options for Hydrogen

Style of Compressor Applications Advantages Disadvantages

Conventional In-line Up to 16,000 RPM - High reliability - Longer footprint

Multi-body High-ratio applications - Robust surge control - Torsionally complex if drive thru
(CO2, gas storage, injection) - High flow with VFD option - Limited to 3-4 bodies (head limits)
- Incorporates barrel HP frame

Externally Geared Up to 16,000 RPM - Optimize speed by stage - Limited number of bodies
Multi-body Designed for hydrogen service - Designed for high head apps - Physical size limit on casing limits flow rates
- Clutch in and out - Flow rate < 180 mmscfd
- Compact design - Potential structurally complex multi-body support
- VFD/VSD option

Two-body Double-Ended Up to 12,000 RPM - Fits well for certain PR - DE motor lead times
(DE) motor Mid-size option for natual gas/CO2/ - High reliability - Limited on pressure ratio
H2 pipeline - High pressure casings

Integrally Geared Up to 30-50k RPM - Optimized speed by stage - Surge control can be catastrophic
Contrifugal Compressor Air compression, cleaner services - Higher head per stage typically - Low reliability due to open design
(IGCC) - Compact single casing - High number of dry gas seal components
- High thrust loads on startup
- Sensitive to fouling
- Capital sparing differences

Reciprocating Up to 1,200 RPM - High pressure ratios - Flow rate limits

Compressors Upstream & gathering applications, - Dirtier gases - Some use lubricated for optimum performance
smaller flows < 100 mmfcsd -A ccommodates intercooling well - Potential pulsation + vibration issues

following factors for future hydrogen sealing methods, alternative valve Klaus Brun, Ph.D., is the Director of R&D at Elliott Group;
compression applications: selections, and additional staging. Timothy C. Allison, Ph.D., is the Director of R&D at
„ Frequency of starts/stops – Reciprocating compressors are available Southwest Research Institute (SwRI); Marybeth McBain is
seasonal or daily cycling for hydrogen service in both low- and the Principal Rotating Machinery Engineer at Venture Global
„ Hydrogen purity and possible high-speed options but will struggle to LNG; Stephen Ross is the Manager of Compressor
contaminants meet larger volume flow requirements Development at Elliott Group; and Eugene L. Broerman III is
„ Dry or wet gas for some applications. Centrifugal the Principal Engineer of Fluid Machinery Systems at SwRI.
„ Fixed or variable speed for fixed or compressors for pipeline and storage
variable flow/pressures applications will be capable of higher REFERENCES
1. Allison, T.C., Rimpel, A.M., Smith, N.R., et al. 2022, “Overview of
„ Criticality of service/reliability/ volumetric flow rates but will need to Long-Duration Energy Storage Systems and Technologies,” Proceedings of
durability of units meet the higher head requirements by ASME Turbo Expo, Tutorial GT2022-83425, Rotterdam, The Netherlands.
2. Williams, B., Kurz, R., McBain, M., 2022, SwRI Oil and Gas Machinery
„ Expected site longevity using adaptable multi-body arrange- Lecture Series, “Role of the Oil and Gas Industry in the Hydrogen Economy.”

„ Design adaptability to hydrogen ments. Finally, centrifugal compressor 3. Allison, T., Klaerner, J., Cich, S., et al. 2021, “Power and Compression
Analysis of Power to Gas Implementations in Natural Gas Pipelines with up to
content (if blended H2 and NG designers are working to achieve higher 100% Hydrogen Concentration,” Proceedings of ASME Turbo Expo, Paper

application) tip speeds to overcome the high head GT2021-59398.

4. Hassanpouryouzband, A., Joonaki, E., Edlmann, K., et al. 2020,
required in hydrogen service with fewer “Thermodynamic and transport properties of hydrogen containing streams,”

SUMMARY compressor stages.6 Sci Data 7, 222. https://www.nature.com/articles/s41597-020-0568-6.

5. Kurz R., Allison, T., Brun, K., 2021, “Pipeline Compression for the Hydrogen
Reciprocating and centrifugal compres- Economy”, DOE Seminar.
6. McBain, M., Bauer, Derrick, B., Ross, S., et al. 2022, “Technology Options for
sors are viable options for hydrogen To read the full article, visit turbomachin- Hydrogen Compression,” Proceedings of Gas Machinery Conference 2022:
compression with enhanced and adapted erymag.com.  Fort Worth, TX.

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