Hydrogen Refueling Station Chiller Unit Skid-mounted temperature control system
Views: 30Author: Site EditorPublish Time: 2026-10-20Origin: Site
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Hydrogen Energy Industry Application Cases | HYDROGEN ENERGY CASE
Hydrogen refueling station temperature control solution
Hydrogen refueling cold-fixed safety
Kaydeli Dual-Zone Skid-Mounted Temperature Control System | A Case Study of a German Hydrogen Refueling Station Project
Project Location
Barnim Brandenburg Germany
Temperature control range
-35℃ deep low temperature, +7℃ normal temperature
★Precise temperature control safeguards the entire hydrogen energy chain★
KAYDELI INDUSTRIAL CHILLER
01 | PROJECT OVERVIEW | Project Overview
Two temperatures behind a single injection
Hydrogen refueling stations are the link closest to users in the hydrogen energy "production-storage-transportation-refueling-use" chain, and also the link most sensitive to temperature.
On September 23, 2026, in Ostender Höhen, Barnheim, Brandenburg, Germany, under a clear sky, two Kaydeli air-cooled chiller units were positioned side by side in a skid-mounted configuration, providing a cooling source for two process loops at the same hydrogen refueling station. One unit stably delivers refrigerant into a deep cryogenic zone of -35°C to pre-cool the hydrogen before it reaches the refueling nozzle ; the other unit delivers ambient temperature (7°C) cooling water to the compressor and auxiliary loops to remove the heat generated during compression and heat exchange.
The original operating readings for the day were displayed on the on-site unit screens: the outlet liquid temperature of the cryogenic unit was -31.0℃ (set to -30.0℃), and the outlet liquid temperature of the ambient temperature unit was 8.4℃ (set to 7.0℃); both units simultaneously displayed the German status message "Das Kühlsystem ist normal" – the cooling system is normal .
-30.0℃
Deep Cryo Setpoint KDC S-040SA
-31.0℃
The actual cryogenic liquid discharge test has entered the target range.
7.0℃
Normal temperature setpoint KDC S-030SA
8.4℃
The actual circuit for liquid outlet at room temperature is operating normally.
Project Information OverviewPROJECT INFO
Place
Barnim County, Brandenburg, GermanyOstender Heights
time
September 23, 202611:28-11:29 Beijing Time
form
Ambient temperature + cryogenic dual-skid unitTwo pieces of equipment are arranged side by side in the same field.
air coolingNo cooling tower or circulating water network required
Certification
CE marking (visible on the device)Compliant with EU market access requirements
02 | Industry Insight |
Why is precise temperature control indispensable for hydrogen refueling stations ?
The process of adding hydrogen is essentially a race against temperature.
1
Adding fuel immediately raises the temperature (JOULE-THOMSON)
When high-pressure hydrogen is released from the hydrogen storage tank assembly and expands through the hydrogen refueling machine into the on-board hydrogen storage tank, a significant temperature rise occurs due to the Joule-Thomson effect . The faster the refueling speed and the higher the pressure level, the more drastic the temperature rise, while the on-board hydrogen storage tank has an upper limit to its operating temperature.
2
The standard has hard constraints , SAE J2601.
The international standard SAE J2601 sets pre-cooling levels for 70MPa rapid refueling: T40 (-40℃), T30 (-30℃), and T20 (-20℃) . To cool the hydrogen to the target temperature before it enters the hydrogen storage tank, a cryogenic cold source capable of long-term continuous operation is required .
3
Dual- zone temperature control is a necessity.
The areas requiring cooling within the station extend far beyond just the hydrogen refueling nozzle: the diaphragm compressor needs interstage cooling, the hydrogen storage tank filling pipeline requires temperature control, and the hydrogen refueling machine itself needs heat dissipation . This naturally leads to a dual-temperature zone configuration of " normal temperature cooling water + cryogenic refrigerant "—which is precisely the division of labor logic between the two skid-mounted units at the German site.
From hydrogen production, storage, and refueling to end-of-pipe testing, air-cooled chillers are becoming the " common cold source " for the entire hydrogen energy industry chain.
normal temperatureDeep CryoHigh precisionExplosion-proof
03 | Solution Map | Overall Solution Overview
A graphic explaining the cooling solutions across the entire hydrogen energy industry chain
If we break down the industry chain, each segment's heat exchange requirements correspond to a specific temperature control point.
Schematic diagram of centralized cooling across the entire hydrogen energy industry chainKAYDELI SOLUTION MAP
Upstream hydrogen production
Water cooling circuit for alkaline/PEM electrolyzerRectifier/Transformer Water Cooling KitDeoxygenation/drying tower heat exchange coil
Midstream hydrogen storage
Hydrogen compressor interstage coolerCryogenic heat exchange module for liquefaction unitHydrogen storage tank filling and cooling pipeline
Downstream hydrogenation
Hydrogen precooling heat exchange moduleDiaphragm compressor water cooling circuitHydrogen refueling machine with built-in heat dissipation pipes
End detection
High-precision constant temperature heat exchange system for fuel cell test benchGas chromatography detection equipment constant temperature cooling component
The downstream hydrogenation stage, where this case is located , is precisely where both cryogenic precooling and ambient temperature cooling circuits operate simultaneously—this is where the value of the dual-temperature zone skid-mounted solution lies.
04 | SITE RECORD | On-site Recording
Two temperatures on the screen
The unit's human-machine interface is configured in German according to European field usage habits, and the operating parameters are visible on one screen and can be directly read and operated.
KDC S-040SA Cryogenic Unit-35℃ level
liquid outlet temperatureFreezing starting temperature
-31.0℃
Temperature setpointSetting the temperature
-30.0℃
Inlet water temperatureImport temperature
-30.4℃
Plate heat exchangerPlate heat exchangers
-27.1℃
oil temperatureOil temperature
68.7℃
Exhaust temperatureExhaust gas temperature
62.0℃
System water pressurewater pressure
4.6 Bar
Refrigerant levelFluid level
538.2mm
KDC S-030SA ambient temperature unit7℃
liquid outlet temperatureFreezing starting temperature
8.4℃
Temperature setpointSetting the temperature
7.0℃
Inlet water temperatureImport temperature
7.8℃
Plate temperaturePlate change temp
11.3℃
Exhaust temperatureExhaust gas temperature
17.0℃
System water pressurewater pressure
4.4Bar
Refrigerant levelFluid level
581.9 mm
compressor typeAir-cooled vortex
Air-cooled scroll type
German human-computer interfaceConfigured according to the language habits of European customers, local staff can operate directly by reading the screen.
WE!NVIEW Industrial Touch ScreenOperating parameters are displayed on one screen, and settings can be adjusted on-site.
Dual indicator lights for operation and alarmThe green running signal and the red alarm signal are arranged side by side.
Red emergency stop buttonAn emergency stop switch is installed on the front of the fuselage in accordance with on-site safety regulations.
05 | DELIVERY | Delivery Form
Two skid-mounted units for one system
The key step in establishing this overseas site was to convert the dispersed cold sources into two units that could be transported as a whole.
Front view of the entire unit | The Kaydeli brand logo is on the left side of the unit, the CE certification mark is on the right side, and the central part features a dual-screen viewing window and operation indicator area.
Skid-mounted integrated
The compressor, condenser, plate heat exchanger, water pump, electrical control and piping are integrated into the same frame. The factory completes the prefabrication, wiring and pre-commissioning. The whole unit is transported to the site and can be put into place for operation.
Outdoor air-cooled
The unit uses air cooling for condensation, eliminating the need for cooling towers and circulating water networks. For European sites where water resources and civil engineering conditions are limited, this is a lighter and faster way to implement the system.
On-site protection
The unit is located under a white steel structure canopy, with a metal protective net installed on the outside to protect against dust and debris and ensure operational safety, while also providing a passage for daily inspection and maintenance.
Select according to temperature zone
The cryogenic unit uses a screw compressor, while the ambient temperature unit uses a scroll compressor. The units are selected according to their respective evaporation temperature ranges to avoid the efficiency and reliability loss caused by a single unit covering the entire temperature range.
Deep low temperature zone
-35 ℃ level
Air-cooled screw cryogenic unit | KDC S-040SA
Service targets: hydrogen refueling pre-cooling heat exchange modules, liquefaction unit cryogenic heat exchange modules, and hydrogen storage tank filling cooling pipelines.
normal temperature zone
7℃
Air-cooled scroll chiller unit | KDC S-030SA
Service targets: interstage cooling of diaphragm compressors, internal heat dissipation piping of hydrogen refueling machines, and circulating cooling of auxiliary equipment within the station.
Two skid-mounted units are positioned side by side. Under a white steel-framed canopy, metal protective netting is installed on the outside of the units, and the top fan area remains open for heat dissipation.
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