Innovations in Coupling Solutions and Hydrogen Fueling
NEI Magazine sits down with Gerhard Kopplin, Technical Director, MannTek, a leading innovator in providing advanced coupling solutions across multiple industries, with a prominent focus on the oil and gas sector. For many years, MannTek has been at the forefront of developing products that are integral to applications in fuel handling, aviation, military, marine, and offshore installations. We discuss many topics including their LH2 (liquid hydrogen) fueling technology, playing a pivotal role in pioneering projects such as the world’s first sLH2 refueling station.
Let’s start by explaining MannTek’s credentials and experience in terms of its products and services for the oil and gas sector. Additionally, we will discuss the breadth of the company’s experience, how long it has been active, and its reach.
“MannTek has established itself as a leader in providing innovative and reliable coupling solutions for a variety of industries, including the oil and gas sector,” says Gerhard Kopplin. MannTek’s products play a crucial role in diverse applications such as fuel handling, aviation, military, marine, and offshore installations. Nearly two decades ago, the company expanded its product range to include gas handling solutions and extended its expertise to cryogenic gases over ten years ago. Kopplin highlights, “Our commitment to excellence is evident in our customized product offerings, tailored to meet the specific needs of our customers. ”MannTek’s global presence is bolstered by a network of distributors and OEMs, ensuring proximity to customers and the ability to provide superior service. “Our dedication to service and training is unmatched, and we pride ourselves on our ability to adapt and respond to the unique challenges of the oil and gas industry,” notes Kopplin. With a history spanning over 20 years, MannTek has a proven track record of delivering the quality and performance that clients rely on. Delving into the diverse range of couplings MannTek provides across various industries, showcasing their unique purposes and applications, Kopplin continues.
“MannTek offers a diverse range of couplings designed to meet the specific needs of various industries, ensuring safety, efficiency, and reliability, Among these, the Dry Disconnect Couplings are a standout, primarily utilized in the chemical and petrochemical sectors, MannTek’s largest market segment.” Kopplin notes, “These couplings facilitate secure and quick connections, minimizing spillage during transfer processes.”
Safety Breakaway Couplings serve as essential emergency release systems, safeguarding hoses in drive-away incidents.
“This feature is crucial for preventing hazardous spills and ensuring operational safety,”
Kopplin emphasizes.
Dry Gas Couplings, predominantly used for LPG distribution, are standard equipment for loading and unloading gas rail tankers and filling gas road tankers, adhering to European EN standards.
For handling cryogenic liquefied gases, MannTek has developed Dry Cryogenic Couplings. “These are instrumental in the ‘bunkering’ process, where ships are fueled with Liquefied Natural Gas (LNG),” Kopplin explains. The push for new international regulations aimed at reducing greenhouse gas emissions in the shipping industry has led to the creation of this new market segment.
Lastly, MannTek’s Full-Flow Ball Valves cater to a niche market. “These lightweight aluminum ball valves are ideal for road tankers delivering fuel to stations, reducing the overall weight of the truck and contributing to increased fuel efficiency,” says Kopplin. Each coupling type is engineered with precision to ensure optimal performance and address the unique challenges presented by different applications within the industry.
NEI Magazine: What are the primary applications of liquid hydrogen in various industries?
“Liquid hydrogen is currently being explored for its potential applications across various industries, particularly for medium to long-range distances,” Says Kopplin. This exploration extends to the transportation sector, encompassing trucks, ships, and aerial vehicles. The industry’s interest in liquid hydrogen is driven by its ability to store energy compactly, making it advantageous for both mobile and stationary applications. “In the context of fueling stations, liquid hydrogen can serve as an efficient storage medium, potentially revolutionizing the refueling infrastructure for vehicles that run on this clean energy source,” Kopplin notes.
For energy-intensive industries, such as steel production and foundries, liquid hydrogen offers a sustainable alternative for processes requiring high temperatures, which are traditionally reliant on fossil fuels. Additionally, liquid hydrogen is being considered for its role in decarbonizing various sectors, contributing to the reduction of greenhouse gas emissions. “Its application in industries that demand a consistent and reliable energy source for heating purposes is also under evaluation, highlighting its versatility and potential as a future energy carrier.”
NEI Magazine: How far along are MannTek LH2 solutions? For example, are they already available for field testing?
“MannTek is at the forefront of LH2 technology, actively participating as a development partner in several pioneering LH2 projects,” says Kopplin. The company is currently conducting field tests focused on truck fueling and ship bunkering applications. “The initial results have been promising, demonstrating the anticipated performance and efficiency of our solutions,” Kopplin notes, adding that this success has sparked considerable interest, leading to numerous inquiries and requests.
Additionally, other market stakeholders have initiated their own trials, and the potential for airborne applications of liquid hydrogen is being explored, assessing its handling and utility. MannTek’s contribution extends beyond couplings to include the implementation of complete transfer lines. “Our automated solutions are designed to facilitate operation with minimal manual intervention, enhancing safety and efficiency,” says Kopplin.
MannTek’s commitment to innovation is evident in its approach to LH2 solutions.
“We are not only developing cutting-edge technology but also supporting its integration into the existing infrastructure, ensuring a seamless transition to cleaner energy sources.”
In recent years, significant advancements in technology have been made to improve the efficiency and cost-effectiveness of liquid hydrogen production and use.
“Advancements in liquid hydrogen technology are primarily focused on ensuring safe handling and improving the efficiency and costeffectiveness of its production and use,” says Kopplin. While the components are currently expensive due to low production quantities, Kopplin notes that the construction of efficient dispensing systems requires surprisingly few components, as validated by field tests indicating that liquid hydrogen solutions are indeed competitive.
Looking ahead, the anticipated increase in demand for liquid hydrogen is expected to drive up production volumes, both of the fuel and the necessary components. “This scale of production is likely to result in a significant reduction in the cost of components, making liquid hydrogen an increasingly attractive option for various industries,” Kopplin explains. In addition to economies of scale, technological innovations are being pursued to optimize the production process of liquid hydrogen. These include developing more efficient electrolyzers, improving insulation materials to reduce boil-off during storage and transport, and integrating renewable energy sources to lower the carbon footprint of hydrogen production. “Furthermore,” Kopplin adds, “the industry is working on enhancing the infrastructure for liquid hydrogen, such as developing more robust pipelines and storage facilities, to support its wider adoption.” These advancements collectively contribute to the growing feasibility of liquid hydrogen as a sustainable and cost-effective energy solution.
LH2 coupling for truck fueling
“LH2 couplings for truck fueling are designed with the highest safety standards to accommodate the unique challenges of handling cryogenic gases at -253 degrees Celsius,” explains Kopplin. Emphasizing the importance of intuitive and safe operation, noting that truck drivers, typically not specialists in cryogenic gases, must be able to operate the coupling effortlessly. “The coupling is automated and controlled by the dispenser system, requiring minimal interaction from the driver,” says Kopplin. The driver’s role is simplified to paying at the terminal and securely connecting the coupling to the tank.
ome systems may include an optional push button for added safety or operational control, but this varies depending on the dispenser builder’s specifications for the fueling process. Kopplin highlights that this approach to design prioritizes user safety and ease of use, ensuring that the fueling process is as straightforward as possible. “By automating the operation of the coupling, we mitigate the potential risks associated with manual handling of liquid hydrogen, providing a seamless and secure refueling experience,” he concludes. This strategic focus on automation not only enhances safety but also ensures a more efficient refueling operation for trucks.
NEI Magazine: Can you talk about Manntek’s role in the building of the worlds first sLH2
refueling station?
“MannTek played a pivotal role in the development of the world’s first sLH2 refueling station, partnering with Daimler Truck to create a specialized coupling for liquid hydrogen fueling,” states Kopplin. Drawing on extensive experience with cryogenic couplings, MannTek was able to quickly adapt and understand the specific requirements for handling hydrogen. “Our proactive approach and ability to rapidly prototype and test our designs in-house were key factors in our success,” Kopplin emphasizes.
The project’s success also stemmed from effective collaboration and open communication with all project partners. “Through joint efforts, we were able to demonstrate that LH2 truck fueling is a viable and safe alternative for long-haul applications, meeting the project’s goals within the estimated timeline.”
MannTek’s contribution, though one part of a larger effort, was crucial in this groundbreaking achievement. “We are honored to have been part of this significant step towards a carbon-neutral, net-zero future, contributing to the development of alternative fuel infrastructures,” Kopplin concludes, underscoring the importance of their role in advancing sustainable transportation solutions.
NEI Magazine: Finally, could you enlighten our readers of a case study where you helped a
client with your solutions?
“MannTek has a rich history of successful case studies where our solutions have greatly benefited our clients,” Highlighting a notable example from about ten years ago: “Our involvement in the first LNG fueled passenger ferry and the first LNG bunker vessel in the world were pioneering steps in the maritime industry’s shift towards cleaner energy sources.” More recently, MannTek has shifted focus to net-zero solutions, such as methanol bunkering and carbon capture projects. Emphasizing the company’s commitment, “Our dedication to innovation and sustainability has been a driving force in helping our clients achieve their goals for a carbon-neutral future.” He concludes by noting that MannTek’s solutions are not just products but are part of a larger movement towards environmental responsibility and energy efficiency, demonstrating the company’s pivotal role in advancing sustainable technologies.
This article was written by New Energy Innovation and was published in their summer addition. You can read the original here: New Energy Innovation Summer 2024.