H₂PLEX – Trailer Filling is SAFE’s integrated hydrogen compression solution specifically developed for high-capacity trailer filling applications, both for on-site hydrogen production and virtual pipeline configurations.

The system combines three sequential compressor skids — MDE 30, DDE 26 and MDH 85 — to provide an integrated multi-stage compression process capable of increasing hydrogen pressure from the electrolyzer side up to 500 barg.

Each compressor skid features 100% redundancy, with two cylinders configured as one active and one standby unit, supporting high system availability and simplified maintenance.

H₂PLEX is designed to provide operational flexibility according to hydrogen production and demand. Its PID flow-proportional control automatically adapts compressor operation to variations in electrolyzer output, while its dual-feed capability allows the system to operate either directly from the electrolyzer or from buffer storage.

For higher demand, the system can operate in parallel mode, increasing the total hydrogen flow rate up to 90 kg/h.

Pre-engineered for integration with electrolyzers up to 5 MW, H₂PLEX provides a compact, modular and scalable solution for hydrogen production sites requiring reliable high-pressure trailer filling.

Key features

Integrated multi-stage compression: hydrogen compression up to 500 barg

High flow rate: 45 kg/h in standard operation

Parallel operation: up to 90 kg/h total hydrogen flow

100% redundancy: one active and one standby cylinder on each compressor skid

PID flow-proportional control: automatically adapts compression capacity to fluctuations in electrolyzer output

Dual-feed capability: automatic management of hydrogen supply from the electrolyzer or buffer storage

Parallel-feed operation: supports peak hydrogen demand and increased trailer filling capacity

Scalable architecture: pre-engineered for electrolyzer installations up to 5 MW

Maximum system capacity: up to 1,074 Nm³/h

Modular and pre-engineered design: developed to simplify integration into hydrogen production and logistics facilities

Compression System Configuration

Compressor Skid

Inlet Pressure

Outlet Pressure

Flow Rate

Redundancy

MDE 30

12–20 barg

45 barg

45 kg/h

1 active + 1 standby

DDE 26

45 barg

195 barg

45 kg/h

1 active + 1 standby

MDH 85

195 barg

500 barg

45 kg/h

1 active + 1 standby

Parallel operating mode: up to 90 kg/h total hydrogen flow with all cylinders in operation.

Technical Specifications

Application: Hydrogen trailer filling

Compression architecture: Integrated 4-stage compression system

Compressor skids:MDE 30 + DDE 26 + MDH 85

Overall pressure range: From approximately 15 barg up to 500 barg

Nominal flow rate: 45 kg/h

Maximum flow rate – parallel mode: 90 kg/h

Control system: PID flow-proportional control

Hydrogen supply: Electrolyzer and/or buffer storage

Maximum electrolyzer capacity: Up to 5 MW

Maximum system capacity: 1,074 Nm³/h

Redundancy: 100% – 1 active + 1 standby cylinder per skid

Safety architecture: SIL2

Applicable safety standards: IEC 61508 / IEC 61511

Emergency venting design: API 521

Control and Operational Flexibility

PID Flow-Proportional Control: The control system adjusts compressor operation according to the available hydrogen flow, ensuring stable performance even when electrolyzer output fluctuates.

Dual-Feed Capability H₂PLEX can automatically manage hydrogen supply from two sources:

Directly from the electrolyzer
From buffer or residual hydrogen storage

This provides increased operational flexibility and allows compression to continue according to site production and storage conditions.

Parallel-Feed Operation: During periods of peak demand, the system can operate with all available cylinders, increasing total hydrogen throughput up to 90 kg/h.

SIL2 Safety Architecture: H₂PLEX incorporates a SIL2-oriented safety architecture covering:

Emergency Shutdown (ESD) supervision
Venting logic management
Fault detection and monitoring
Fault-tolerant system components

The safety architecture is designed in accordance with IEC 61508 and IEC 61511.

Emergency Venting System: The emergency venting system is designed in accordance with API 521 and includes:

Dedicated hydrogen vent stack
Blow-down system
Safety and venting valves
Thermal radiation protection for the areas surrounding the venting system
Engineering provisions for controlled hydrogen release events

H₂PLEX – Trailer Filling Compression System