LHYVE-Cycle – Intelligent maintenance concepts for hydrogen-bearing systems

The partners in the LHYVE-Cycle project are developing an innovative system for flushing hydrogen tanks to make the commissioning and decommissioning of hydrogen systems safer, faster and more economical.

The utilisation of hydrogen systems in applications such as heavy-duty vehicles, as well as for the transport of hydrogen, requires safe and cost-effective maintenance and repair processes. In particular, working with hydrogen storage systems and fuel cell systems presents new technical challenges for workshops, operators and manufacturers.

Flush tanks with nitrogen

For maintenance and repair work, hydrogen-bearing systems have to be taken out of operation and then put back into operation. Up to now, this has been very time-consuming, and depressurising and flushing the storage tanks in particular consumes a lot of nitrogen (_N2) and hydrogen (_H2). In the new LHYVE-Cycle project, a new type of flushing unit for hydrogen tanks is now being developed with an innovative simulation and AI-supported concept. This should make the commissioning and decommissioning of hydrogen systems safer and faster and consume less gas.

During decommissioning, the hydrogen in the tank is displaced with nitrogen until its concentration is safely below the explosion limit. During (re)commissioning, oxygen from the ambient air in newly installed or opened storage tanks must first be removed with nitrogen before the tank can be filled with hydrogen. To meet quality specifications, the nitrogen must be completely removed from the tank by purging with hydrogen.

Until now, these steps have been carried out using manually controlled pressure change cycles, which are based on highly simplified assumptions, are hardly monitored or checked and consume large quantities of gas – with limited process reliability and reproducibility at the same time.

ZBT’s hydrogen test site with numerous structures and containers

Automated flushing unit

The newly launched LHYVE-Cycle project addresses this very issue and is developing an innovative, comprehensive concept that combines modern simulation, intelligent data processing, and new technical solutions into a holistic maintenance approach. At the heart of the project is the goal of replacing the gas-intensive pressure-cycle purging of hydrogen storage systems – which has traditionally been performed manually – with a controlled, reproducible, and resource-efficient process.

A holistic system consisting of a gas dynamic stratification model, a digital knowledge base with AI support and an automated system for commissioning and decommissioning is being developed for this purpose. This should enable operators to work safely, faster and with significantly lower gas consumption in the future – both stationary in workshops and mobile in the field.

Main dispenser at the hydrogen test filling station at the ZBT

Interdisciplinary Collaboration

The project is being implemented by an interdisciplinary consortium:

BHFM Technologies is developing the technical core system, consisting of a new type of flushing module, a secondary gas treatment system and a modular service unit for zero-emission vehicles.
Amperias is implementing the digital infrastructure, including the database, AI model, cloud connection and a user-oriented user interface, which is used to control, document and further develop all maintenance processes.
The ZBT is responsible for the scientific and technical groundwork and creates the modeling, supplies the measurement technology and carries out the validation.

Two people at the control panel of the hydrogen test filling station at the ZBT - The Hydrogen and Fuel Cell Center

Over the course of the three-year project, the partners will carry out simulations, measurement campaigns, prototype construction and field tests. The ZBT is focusing on

the development of the CFD-based stratification model (CFD = Computational Fluid Dynamics),
the construction of a test stand that will be integrated into the hydrogen test field,
Instrumentation and Analysis of High-Pressure Vessels
as well as the validation of the model and process parameters under realistic conditions.

The data obtained is continuously fed into the digital maintenance concept and forms the basis for scalable, safety-relevant applications along the entire hydrogen value chain. LHYVE-Cycle thus makes an important contribution to the technical maturity, availability and cost-effectiveness of future H₂ mobility.

Project information

Project title: LHYVE-Cycle – Development of a maintenance and repair concept supported by artificial intelligence

Project partners:

Amperias, Cologne
BHFM Technologies, Willich (project coordination)
ZBT, Duisburg

Project duration: 1 October 2025 – 30 September 2028

Project volume: approx. € 3.2 million

Funding: GreenEconomy.IN.NRW (ERDF/JTF program NRW 2021-2027)

The project is funded by the European Union.

Contact

Project manager

Lukas Willmeroth

+49 203 7598-2190

l.willmeroth@zbt.de

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