In a recent hydrogen generation project in the Middle East, 190 Pyropress Perseus Ex pressure switches have been provided for HVAC systems and chiller units. This initiative supports the production of green hydrogen for domestic use, with surplus hydrogen routed to a dedicated facility for ammonia synthesis and export. Over 100 more explosion proof pressure switches are being integrated into chillers used in the hydrogen-to-ammonia conversion project.
As global energy systems transition toward low-carbon alternatives, hydrogen has emerged as a key enabler of clean energy. Yet, one of the most pressing challenges in scaling hydrogen infrastructure lies in its safe and efficient transport. Hydrogen’s small molecular size allows it to permeate many materials, and it can cause embrittlement in stainless steel, posing significant engineering challenges.
Increasingly, ammonia is being adopted as a hydrogen carrier, offering a practical solution for long-distance shipping and storage. Due to hydrogen’s volatility and the difficulty of transporting it over long distances, customers are turning to hydrogen-rich ammonia, which is more stable. The hydrogen is then extracted closer to the point of use, helping to overcome logistical and safety barriers.
Ex switches in HVAC chillers for ammonia synthesis and export
In the hydrogen-to-ammonia conversion chain, HVAC chillers are used to cool reaction gases and condense ammonia during synthesis and separation stages. However, the process involves handling highly flammable substances. Hydrogen, in particular, has a wide flammability range and low ignition energy making it extremely volatile in air. Ammonia, while less flammable, still poses significant risks under high pressure and elevated temperatures.
Operating in hazardous environments, these chillers must meet stringent safety standards, including ATEX and IECEx certifications, to mitigate the risk of ignition. Electrical components within these systems, such as pressure switches, must be explosion proof and designed to prevent sparking or heat generation that could ignite flammable gases.
By continuously monitoring and controlling pressure levels, Pyropress flameproof switches help maintain system integrity and prevent certain conditions.
The Ex ia and Ex d pressure switches used in this project feature black anodised aluminium housings, offering both corrosion resistance and durability in harsh environments.
SPOTLIGHT ON EX PRESSURE SWITCHES USED IN HVAC APPLICATIONS
For pressure control in hazardous areas:
- Perseus™ flameproof and intrinsically safe pressure switches are Ideal for OEMs building HVAC systems for hazardous areas. They have multiple switch configurations, robust housing and proven long-term reliability (SIL 2 rating) in tough environments.
What is hydrogen and how flammable is it?
Hydrogen is the most abundant element on earth and capable of chemical reactions that generate energy. It’s flammable and, like all other flammable material, an explosion can occur when all three parts of the ignition triangle come together.
Hydrogen explodes with enormous energy, requiring only a small amount of gas to cause significant damage which can lead to melting and further fires and explosions in the surrounding areas. It has a very low minimum ignition energy (MIE) of just 0.0017 millijoules (mJ) at a stoichiometric mix.
Hydrogen’s extremely large explosion range and high flame velocity also means the resulting rapid pressure increase of hydrogen explosions are of particular importance for explosion protection specifications, which are different to that of natural gas.
Why Pyropress Ex switches and transmitters for Hydrogen Applications?
Pyropress Ltd and its channel partners have extensive experience designing, manufacturing and supplying instrumentation to hydrogen generation and storage facilities, including gigafactories and pilot plants. Pyropress explosion proof switches and transmitters are trusted by OEMs and system integrators worldwide for their reliability in extreme conditions, from –50degC to over 100degC to pressures up to 1500Bbar.
In this project, Pyropress instrumentation supports both the hydrogen generation phase and the downstream ammonia conversion. By enabling precise pressure control in HVAC systems, Pyropress explosion proof pressure switches contribute to the safe and efficient operation of a complex energy value chain.
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