Simulation of multistage hydrogen compression for different discharge pressures with waste heat recovery based on ORC technology

Zenodo (CERN European Organization for Nuclear Research)

Abstract

The increasing demand for hydrogen as a low-carbon energy carrier highlights the importance of efficient compression technologies, particularly for high-pressure-storage and transport applications. This study investigates multistage mechanical hydrogen compression systems designed for final discharge pressures of 350 bar and 700 bar, coupled with waste heat recovery using an Organic Rankine Cycle (ORC). A steady-state simulation model is developed in Aspen Plus to evaluate system performance, including compressor operation, intercooling requirements, and thermal energy recovery potential. The compression systems are optimized with respect to interstage pressure ratios to minimize total compression work while respecting the operational constraint of maximum discharge temperature. The thermal energy rejected in the intercoolers is recovered and utilized as the heat source for the ORC, which is modeled to assess its capability for electricity generation. Key performance indicators include specific compression work, intercooler heat duty, ORC power output, and overall electricity savings. The results indicate that higher discharge pressures lead to increased compression work, while optimized staging maintains pressure ratios within acceptable operational limits. The four-stage configuration exhibits higher waste heat recovery potential compared to the five-stage system due to higher temperature levels in the intercooler streams. The integration of the ORC system results in very modest electricity savings, ranging from 1.4–2% for the four-stage system and 0.98–1.5% for the five-stage system. Overall, the study demonstrates that while waste heat recovery from hydrogen compression is technically feasible, its effectiveness is strongly dependent on the temperature level of the available heat. The findings provide useful insights into the thermodynamic integration of compression and recovery systems, supporting the design of more energy-efficient hydrogen infrastructure.

Authors 4

1. Alexandra Pavlidi

   National Centre of Scientific Research "Demokritos"

   Affiliation as printed

   National Centre of Scientific Research "Demokritos"

2. Konstantinos Braimakis

   National Technical University of Athens

   Affiliation as printed

   National Technical University of Athens

3. George Tsatsaronis Aachen

   Technische Universität Berlin · Desert Research Institute · Tennessee Technological University · RWTH Aachen University

   Affiliation as printed

   Tennessee Technological University

   Desert Research Institute

   RWTH Aachen University

   Technische Universität Berlin

4. Sotiriοs Karellas