Periodic Reporting for period 4 - COSMHYC DEMO (COmbined Solution of Metal HYdride and mechanical Compressors: DEmonstration in the Hysoparc green H2 MObility project)
Período documentado: 2025-01-01 hasta 2025-09-30
Hydrogen technologies are essential for clean mobility, especially in heavy-duty transport. However, refuelling infrastructure is developing slowly, and hydrogen compression remains a major challenge, as compressors are the most complex and costly element of an HRS, both in investment and reliability.
To address this, the COSMHYC consortium developed an innovative hybrid compression system combining metal hydride and mechanical compressors. Designed for hydrogen mobility and suitable for applications like filling centres, the solution had reached TRL 5 in previous projects. COSMHYC DEMO aimed to advance it to TRL 7 by validating real-life operation. The partners not only improved, built, and tested the system, but also constructed and commissioned a full HRS that served as the demonstration site. This process provided valuable experience in infrastructure construction and authorisation procedures. The compression solution and all HRS equipment are now CE-certified and compliant with the latest refuelling and hydrogen purity standards.
The new HRS, within the HYSOPARC project near Tours, France, is central for local hydrogen mobility. Operating since 2024, the dual-pressure station serves multiple 700-bar or 350-bar vehicle types, incl. a 700-bar garbage truck from the HECTOR project.
The demonstration ran for over a year using trailer-supplied green hydrogen. A dedicated monitoring system on both compressors confirmed the technical feasibility of integrating and operating the hybrid solution and enabled data collection for a techno-economic assessment. The analysis showed strong performance, flexibility, and significant reductions in maintenance and operating costs versus current technologies.
COSMHYC DEMO has therefore strengthened the basis for hydrogen mobility in the CCTVI region and demonstrated compression technology with high potential to enhance the economic, environmental, and societal benefits of hydrogen deployment.
To address this, the COSMHYC consortium developed an innovative hybrid compression system combining metal hydride and mechanical compressors. Designed for hydrogen mobility and suitable for applications like filling centres, the solution had reached TRL 5 in previous projects. COSMHYC DEMO aimed to advance it to TRL 7 by validating real-life operation. The partners not only improved, built, and tested the system, but also constructed and commissioned a full HRS that served as the demonstration site. This process provided valuable experience in infrastructure construction and authorisation procedures. The compression solution and all HRS equipment are now CE-certified and compliant with the latest refuelling and hydrogen purity standards.
The new HRS, within the HYSOPARC project near Tours, France, is central for local hydrogen mobility. Operating since 2024, the dual-pressure station serves multiple 700-bar or 350-bar vehicle types, incl. a 700-bar garbage truck from the HECTOR project.
The demonstration ran for over a year using trailer-supplied green hydrogen. A dedicated monitoring system on both compressors confirmed the technical feasibility of integrating and operating the hybrid solution and enabled data collection for a techno-economic assessment. The analysis showed strong performance, flexibility, and significant reductions in maintenance and operating costs versus current technologies.
COSMHYC DEMO has therefore strengthened the basis for hydrogen mobility in the CCTVI region and demonstrated compression technology with high potential to enhance the economic, environmental, and societal benefits of hydrogen deployment.
The project began in 2021 with an analysis of end-user needs and the development of an integration concept combining a metal hydride compressor (MHC) with a mechanical compressor (MC):
• The MHC was designed as a supply compressor raising hydrogen to 450 bar. The prototype, built into a 20-foot container, incorporated safety requirements, new hydride reactors with optimised heat exchangers and metal hydrides with rare-earth-free compositions.
• The two-stage MC prototype features two compression heads and a redesigned oil and crank system for manufacturability and reliability.
Following preparatory studies, extensive construction in Period 2 led to the installation of the new HRS. The MHC received its operating permit in mid-2024 and was installed and commissioned in early 2025. A central gas hub was designed to interconnect subsystems and manage hydrogen flows. The overall concept also includes a future on-site hydrogen filling centre to be launched once green hydrogen production becomes available.
In Period 4, CE certification of the MHC was completed and related demonstration activities began. A monitoring system on both compressors collected detailed operational data (HRS operation, FCEV refuelling, reliability metrics, mass/volume flows). All data were stored for in-depth performance analysis. The techno-economic model addressed cost, energy consumption, and scale-up assessments. A life-cycle analysis confirmed that the MHC has lower environmental impact due to minimal electricity use and waste-heat recovery potential.
The HRS also served as a dissemination platform, hosting targeted events and visits, incl. an avant-première and official opening for regional stakeholders and potential early adopters. Toward project completion, the consortium received major recognition: second place in the 2025 IEA Hydrogen TCP Award of Excellence for COSMHYC DEMO and the 2025 Hy-FCell Product & Market Award for EIFHYTEC.
A detailed exploitation plan was finalised, defining the steps needed to reach TRL 9 and scale up MHC production beyond the project.
• The MHC was designed as a supply compressor raising hydrogen to 450 bar. The prototype, built into a 20-foot container, incorporated safety requirements, new hydride reactors with optimised heat exchangers and metal hydrides with rare-earth-free compositions.
• The two-stage MC prototype features two compression heads and a redesigned oil and crank system for manufacturability and reliability.
Following preparatory studies, extensive construction in Period 2 led to the installation of the new HRS. The MHC received its operating permit in mid-2024 and was installed and commissioned in early 2025. A central gas hub was designed to interconnect subsystems and manage hydrogen flows. The overall concept also includes a future on-site hydrogen filling centre to be launched once green hydrogen production becomes available.
In Period 4, CE certification of the MHC was completed and related demonstration activities began. A monitoring system on both compressors collected detailed operational data (HRS operation, FCEV refuelling, reliability metrics, mass/volume flows). All data were stored for in-depth performance analysis. The techno-economic model addressed cost, energy consumption, and scale-up assessments. A life-cycle analysis confirmed that the MHC has lower environmental impact due to minimal electricity use and waste-heat recovery potential.
The HRS also served as a dissemination platform, hosting targeted events and visits, incl. an avant-première and official opening for regional stakeholders and potential early adopters. Toward project completion, the consortium received major recognition: second place in the 2025 IEA Hydrogen TCP Award of Excellence for COSMHYC DEMO and the 2025 Hy-FCell Product & Market Award for EIFHYTEC.
A detailed exploitation plan was finalised, defining the steps needed to reach TRL 9 and scale up MHC production beyond the project.
The equipment demonstrated within the project represents the first real-life integrated refuelling station that combines a mechanical compressor with a thermochemical compression solution. Moreover, it is the first system to integrate the functionality of using the thermochemical compressor as a filling centre. All components, as well as the fully integrated installation, obtained CE certification. Also CEP-SAT tests and hydrogen purity tests were carried out, confirming full compliance with the latest European regulatory requirements for hydrogen refuelling infrastructure. Those are significant milestones for future commercial exploitation.
For the compressive MH reactors, approximately two tonnes of metal hydride were produced, likely the largest volume ever produced in the EU for hydrogen applications. The MH compressive reactor designs were improved to reach specified thermal-related performance while maintaining cost constraints. In total, 28 CE-certified compressive MH reactor vessels were delivered in eight racks for integration into the MHC
In its COSMHYC DEMO configuration, EIFHYTEC’s MHC was designed to supply both the HRS and a filling centre. Built in 2024 in EIFHYTEC’s workshop, it was installed and commissioned on site in less than one month, demonstrating the compactness of the containerised design, which remains modular in terms of pressure and flow. The design also facilitates maintenance and reduces civil-engineering requirements, as no vibration mitigation is needed. The demonstration showed that this ISO 14687:2025 grade-D-ready machine can compress up to 250 kgH2/day in two stages from 30 to 450 bar. In total, the demonstration recorded 46,000 hours of availability and compressed 1500 kg of hydrogen with stable performance. By the end of the project, the successful demonstration of this TRL7 prototype confirmed the market readiness of EIFHYTEC’s thermochemical compression technology
Finally, the demonstrated compression solution will contribute to significantly improve the economic viability of Hydrogen Refuelling Stations by allowing a TCO reduction. By combining all its advantages, the COSMHYC compression solution will significantly contribute to the faster deployment of hydrogen mobility and thus to the clean energy transition.
For the compressive MH reactors, approximately two tonnes of metal hydride were produced, likely the largest volume ever produced in the EU for hydrogen applications. The MH compressive reactor designs were improved to reach specified thermal-related performance while maintaining cost constraints. In total, 28 CE-certified compressive MH reactor vessels were delivered in eight racks for integration into the MHC
In its COSMHYC DEMO configuration, EIFHYTEC’s MHC was designed to supply both the HRS and a filling centre. Built in 2024 in EIFHYTEC’s workshop, it was installed and commissioned on site in less than one month, demonstrating the compactness of the containerised design, which remains modular in terms of pressure and flow. The design also facilitates maintenance and reduces civil-engineering requirements, as no vibration mitigation is needed. The demonstration showed that this ISO 14687:2025 grade-D-ready machine can compress up to 250 kgH2/day in two stages from 30 to 450 bar. In total, the demonstration recorded 46,000 hours of availability and compressed 1500 kg of hydrogen with stable performance. By the end of the project, the successful demonstration of this TRL7 prototype confirmed the market readiness of EIFHYTEC’s thermochemical compression technology
Finally, the demonstrated compression solution will contribute to significantly improve the economic viability of Hydrogen Refuelling Stations by allowing a TCO reduction. By combining all its advantages, the COSMHYC compression solution will significantly contribute to the faster deployment of hydrogen mobility and thus to the clean energy transition.