Alfa Laval Powers Hydrogen Mobility with Breakthrough Cooling Technology in RHeaDHy Project
Alfa Laval has successfully contributed to the European RHeaDHy project by developing a cutting-edge high-capacity cooler that enables rapid and reliable hydrogen refueling for heavy-duty vehicles and trucks.
As the transportation sector transitions to cleaner energy sources, heavy vehicles face unique challenges. Battery systems often fall short in delivering the sustained power required for long-haul operations, and even fuel cells can struggle to meet peak performance demands. Moreover, the economic viability of these vehicles depends on maximizing uptime – idle trucks and excavators mean lost revenue.
The RHeaDHy project addresses this critical need by focusing on fast, dependable hydrogen refueling solutions. Alfa Laval’s innovation plays a central role in achieving the project’s goal: refueling heavy vehicles in under 10 minutes.
One of the key engineering challenges is maintaining high refueling speeds while accommodating unpredictable vehicle arrival patterns. Whether one truck arrives per hour or six, the thermal load on the cooling system varies dramatically. These fluctuations create significant thermal stress within the heat exchanger, demanding a solution that is both high-performing and fatigue-resistant.
Alfa Laval’s R&D team rose to the challenge, mastering the internal stress dynamics of hydrogen cooling systems. The result is the Hybloc18, a robust, high-performance heat exchanger capable of supporting refueling rates of 18 kg/minute. Engineered for durability, the Hybloc18 is built to withstand the demanding fatigue conditions typical of heavy vehicle refueling stations.
“With the Hybloc18, we’re not just enabling faster refueling – we’re helping pave the way for a more sustainable and economically viable future for heavy transport,” said Frédéric Rondet, R&D Project Manager at Alfa Laval.
The RHeaDHy project marks a significant step forward in hydrogen infrastructure, and Alfa Laval is proud to be at the forefront of this transformation.
Heat Exchanger
| Parameter | Value |
| Dimensions | 740 x 400 x 340 mm |
| Weight | 750 kg |
| H2 Fill Rate | 18.0 kg/min |
| Fueling Protocol | SAEJ2601 |
| Design Code | ASME, PED |
| Inspection / Test | ASME, PED |
| HT Plates Qty | 132 plates |
| HT surface | 8.3 m² |
| Design pressure | 1 250 barg |
| Pressure drop (coolant) | 180 kPa |
| Pressure drop (hydrogen) | ~ 1 bar at 232 g/s
inlet conditions 240 bar, 20°C |