A small molecule on a long journey

Hydrogen is the smallest known molecule of our time, and it is precisely this small molecule that is to be the energy source of the future. Although it sounds very promising, it still presents many challenges – particularly in the area of logistics. This is where the research of Fraunhofer IML comes in. In the “H2LogisticsOnRail” project, our little H2 molecule is sent on a long journey that is not only green but smart as well. 

Hydrogen, especially when it is produced in a green manner, plays a major role in Germany’s energy transition and beyond. Until now, our little molecule has been transported either in liquid form by rail, which is eco-friendly but very time-consuming, or in compressed-gas form by road. At this point, a comprehensive logistics solution is needed that meets the standards of intermodal transport and also fulfills the requirements for safe rail transport. 

The solution: a smart hydrogen container that not only provides more safety but also reduces emissions in line with the energy transition. And it also allows a larger quantity of hydrogen to be transported per container unit. This goal is being pursued in the “H2LogisticsOnRail” project by Hexagon Purus, the world’s leading manufacturer of high-pressure hydrogen containers and transport systems, Endress+Hauser, a specialist for measuring instruments, services and solutions for process automation, Infraserv Höchst, the operating company of Industriepark Höchst and a leading industrial service provider for the chemical and pharmaceutical industry, DB Cargo BTT, a European service provider for integrated chemicals, petroleum and hazardous goods logistics, and the experts of Fraunhofer IML. 

“In order to meet the high expectations, we have bundled the best from the fields of hydrogen, logistics and industry together with our partners. Together we have taken on the challenge of developing the transport of the future and putting a smart hydrogen container on rails today,” relates Moritz Tennhoff, research scientist at Fraunhofer IML. 

To transport our little H2 molecule from A to B in the safest and greenest way possible, the gaseous hydrogen is compressed up to 500 bar and put into specially manufactured hydrogen containers. The transport container, which comprises a large number of these hydrogen containers, can be transported safety and eco-friendly via freight train. Or, alternatively and in combination, by inland waterway vessel or truck. To ensure this safety, the container has been equipped with a variety of sensors. Our molecule is monitored very closely over the entire supply chain – whether in regard to location, temperature or pressure. In addition to the basic characteristics of the tank, the software concept developed by Fraunhofer IML and BTT also covers filling, removal and, fittingly, billing. All this information is transferred to a cloud and collected in real time. This allows possible disruptions or unexpected occurrences to be identified early on. In addition, predictions of possible critical cases or the need for maintenance should also be enabled, based on the data collected up to that point. Not only does all of this increase the transparency along the entire multimodal supply chain, but the advantages of ecologically generated hydrogen are fully exploited thanks to environmentally friendly transport.

“In comparison to diesel-powered truck trailers loaded with conventional pressure cylinders, we can reduce CO2 emissions by up to 80 percent at considerably lower costs. There is also a still enormous potential to expand the technology further in the future. A next step could be to expand the container to a temporary fuel station in order to enable stationary deliveries,” Tennhoff discusses further. 

The project, which has been running since the end of 2022, is currently in a pilot phase in which the containers under development are exposed to all kinds of extremes, such as weather-related conditions and ramp tests. As soon as these tests have been completed, the molecule of the future will be sent on its long journey in a smart container for the first time. The produced containers will be installed in another container that is equipped with any tested sensors and transported by DB Cargo BTT under real-world conditions. An initial test route will be the transport to Industriepark Höchst. Data will be generated and evaluated during this test, and adjustments will be made if necessary.

After this final test, the hydrogen containers will be massproduced and then used throughout Germany – from simple transportation from A to B to further multimodal transports. In addition, operative software can be developed from the Fraunhofer IML concept and adapted to the individual needs of different industrial customers.