PNEUMATICS 26 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk For the UK to achieve net-zero, hydrogen has an important role to play. Transport is responsible for nearly a third of the country’s total emissions, and while the EV market is growing, many vehicle operators with longer-distance requirements are looking to hydrogen as an alternative. This summer, the government announced a £500M injection to support building the UK’s first regional hydrogen transport and storage network. While there are six refuelling hubs currently in the UK, five more are scheduled to open by 2027, with plans for up to 30 new hubs by the end of the decade1. In addition to refuelling hubs for commercial vehicles, an increasing number of industry sectors across the UK are integrating their own supply of hydrogen as a power source. From bus operators through to industrial manufacturers as well as construction companies, hydrogen can help organisations achieve their net-zero ambitions, as well as providing a back-up to reinforce energy security. With a current lack of hydrogen pipelines, and limited infrastructure to create hydrogen on-site, road transport is the flexible option. Delivering this off-grid hydrogen supply is a fleet of tube trailers, which also serves the needs of hydrogen storage. This system involves a truckmounted frame holding a bundle of long, thick-walled pressure vessels, typically 612m in length, connected via a manifold. As hydrogen is compressed into the tubes, no additional infrastructure is required to access the gas; when the sealed tubes are opened, flow naturally occurs as a result of the pressure differential. Ultra-high pressure A requirement shared by hydrogen fuelling stations as well as tube trailer transportation and storage is the need for high pressure. In a refuelling station, hydrogen will only move from the station’s storage tanks into the vehicle’s onboard tank if it has a higher pressure. Compression at pressures between 500 to 1000 bar allows for natural overflow into the vehicle tank at a fast flow without needing an additional compressor at the dispenser nozzle. Meanwhile, for hydrogen insertion into tube trailers, compression is raised up to between 350 bar and 500 bar, increasing hydrogen density to a higher level to optimise payload in transportation and storage. To maintain these pressures, and ensure safe storage as well as controlled flow, valve operation is an integral link. At 350 bar and above, this is defined as ultra-high pressure, a significant classification, because to maintain safety and control, this level demands a valve with a reinforced construction. While Understanding valve demands in high pressure hydrogen systems As the use of hydrogen is increasing across the UK’s energy mix, safely controlling its flow is vital to realise its potential as a sustainable alternative. For vehicle refuelling, as well as use across industry, high-pressure and ultra-high-pressure hydrogen flow is vital. Understanding these distinctions and the importance of valve design in high-pressure hydrogen distribution are key to developing the required infrastructure. Tony Brennan, Hydrogen Flow Control Specialist at Bürkert, explains.
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