The AVOGADRO project, coordinated by Iberdrola, includes seven other leading Basque companies in the hydrogen value chain: ABC Compressors, CAF Turnkey & Engineering, Cikautxo, Ingeteam, Lointek, Lumiker Aplicaciones Tecnológicas, and Tratamientos Térmicos TTT.

Hydrogen is an opportunity for Euskadi, as reflected in the strong emphasis on R&D activities in the region, involving both companies and technological centers and universities. This was highlighted by Amaia Martínez Muro, Technology Director of SPRI, at the opening of the event, noting that the Elkartek, Hazitek, and Azpitek hydrogen programs approved since 2021 exceed 41 million euros in support and cover the entire value chain of the sector.

Among these initiatives, AVOGADRO is the main business R&D project addressing the deployment of hydrogen mobility. Its objectives are perfectly aligned with the Basque Hydrogen Strategy, which has set targets for 2030, including a fleet of 20 hydrogen buses, 450 freight transport vehicles of various sizes, and a network of 10 public hydrogen refueling stations. The project began its activities in 2022 with the aim of researching, understanding, and designing critical systems for hydrogen refueling for heavy vehicles and trains. In this regard, among other activities, it has included the analysis of material behavior in contact with hydrogen, the development of new technologies applicable to hydrogen refueling station components, the investigation of fiber optic-based measurement and detection solutions related to safety and monitoring, and the analysis of the process and different configurations for road and rail transport.

Iberdrola, as the project coordinator, has gained significant experience in the sector over the past few years during the construction and operation of the first hydrogen refueling station for bus fleets in Barcelona. This facility, with an electrolysis capacity of 2.5 MW, has allowed Iberdrola to understand hydrogen vehicle refueling technology and identify the needs and challenges related to hydrogen refueling stations.

To address issues of sealing, corrosion, and material embrittlement in the presence of hydrogen, Tratamientos Térmicos TTT, a company dedicated to thermal and surface treatments, has identified the critical components and materials of the hydrogen refueling station to investigate their behavior in contact with hydrogen. Together with Tecnalia, they have developed unconventional thermal treatments for austenitic alloys (AISI 316L). Both entities have worked on the research and laboratory validation of ASPN treatments, which have shown to reduce material degradation and hydrogen leaks.

Regarding hydrogen storage challenges, the rubber and plastic component manufacturer Cikautxo has designed and manufactured a technological demonstrator of a Type IV tank. To do this, the partner analyzed the refueling process and the models currently available on the market, as well as the technology and materials for manufacturing these tanks. The demonstrator was made with PA6 polymer, carbon fiber, and epoxy resin using liner and filament winding manufacturing processes. On the other hand, Lointek, an engineering and pressure vessel manufacturing company, analyzed the storage needs of hydrogen refueling stations to create the conceptual design of a Type I tank. Lointek opted for the P460-ML1 material, welded joint at the manhole, and vertical tank design. Tecnalia conducted hydrogen-induced cracking (HIC) tests, slow strain rate tensile tests in a compressed hydrogen environment (SSRT), and hydrogen toughness tests. The tests indicate that the P460-ML1 material is a promising option for hydrogen storage, but stainless steel recharging for welded joints is not suitable.

Regarding components, Lointek conducted a preliminary study of different pre-cooler types, selecting the shell-and-coil heat exchanger based on this work. The company developed a calculation and validation tool for the conceptual design of this component. ABC Compressors selected reciprocating piston compressors for the hydrogen refueling station due to their good performance. To determine the equipment specifications, ABC Compressors and Tecnalia used a simulation tool for hydrogen supply, compression, and storage. Additionally, a control system for filling tanks at different pressures was developed and validated. Ingeteam was responsible for the power electronics for electrolyzers in hydrogen refueling stations. The manufacturer, in collaboration with Iberdrola, defined the specifications of the electrolyzer and its grid connection in two possible cases, with one and two stacks. The sizing and design tool showed that the main difference between electrolyzers lies in the startup method, a relevant aspect for topology selection. Ingeteam compared different existing topologies, concluding that the most promising topologies are AFE, 12-Pulse TFE, and 12-Pulse DFE + DC/DC.

berdrola and CAF TE have collaborated in the development of CFD simulation models and simulations of the different elements in an HRS (electrolyzer, compressor, storage, dispensers, and vehicle) for road and rail transport. Currently, there are no regulations defining the protocol to be used for refueling heavy vehicles, so each manufacturer defines its own protocol. CAF TE has developed a comprehensive procedure to define the refueling protocol for a heavy vehicle, based on the existing regulations for light vehicles.

Lumiker has designed monitoring solutions based on Bragg technology. The deposition of metallic elements (Pd) with selective properties to hydrogen allows the development of optical sensors to measure hydrogen content. The project partner has also developed prototypes of hydrogen, temperature, and pressure sensors, and an optical interrogator BAST-H2, which have been tested at Lumiker and Tecnalia facilities. The sensor data is displayed on the specific graphical interface for AVOGADRO. The event was organized by the Energy Cluster and Tecnalia, in collaboration with the AVOGADRO project partners, and included discussion spaces to compare the work done and its potential usefulness with the attending companies, in order to promote collaboration opportunities.

The project has had the collaboration of several agents from the Basque Network of Science, Technology, and Innovation (RVCTI), such as Tecnalia, Ikerlan, Cikatek, Gaiker, and the Basque Energy Cluster.