The HyGGeTM 500P electrolyzer
The HyGGe™ 500P is a revolutionary, fully integrated electrolyzer system, engineered from the ground up to deliver consistent, high-efficiency hydrogen production. Housed in robust containerized units, it is designed for straightforward outdoor installation and simple, reliable operation at the customer’s site. This water electrolyzer is purpose-built for safety, reliability, and long-term durability.
“It took courage and dedication from our experienced teams to design the HyGGe™ 500P water electrolyzer from a blank sheet. This freedom from legacy constraints allowed us to innovate boldly. The result: our proprietary HIFI™-powered cell stack and a fully integrated system engineered for reliability, robustness, and longevity.”
Roel De Maeyer – CEO Exion Hydrogen
The HyGGeTM 500P water electrolyzer
Hover over the parts of our unit to discover more
Discover the parts of the HyGGe™ 500P
and their functions
Main Electrolyzer Unit Housing
The HyGGe™ 500P electrolyzer is housed in a robust 45-ft HighCube container with a metal floor, insulated walls and ceiling, and ample air inlets and outlets to ensure optimal ventilation. A gas-tight partition divides the container into two distinct sections.
The first section is ATEX-zoned, where pure water is split into its core components—hydrogen and oxygen. After further purification, the gases are directed to the respective user lines or safely vented.
The second section is non-ATEX and contains the integrated Data Control Module. This module manages the pump systems for the dry cooler, circulation heater controls (keeping the unit frost-free when not in operation), ventilation outlets, and the electrical control panel. It is also equipped with an automatic HVAC system that ensures consistent operation in both cold winters and hot summers.
Designed with practicality in mind, the HyGGe™ 500P can be transported conveniently using standard ISO shipping and handling procedures.
Electrolyzer Rooftop Frame
The 45-ft rooftop frame on top of the main unit consists of both an open and a covered section. The open area houses the Heat Exchange System (HXS), which includes a Dry Cooler for system cooling and a Chiller for gas cooling—cooling the oxygen before venting and the hydrogen before and during the purification phase.
The enclosed utility room houses the Water Purification System, featuring a Reverse Osmosis unit that converts tap water into demineralized water with a conductivity of 0.1 µS/cm, along with a dedicated electrical distribution cabinet and the Instrument Air Compressor. A dedicated air-conditioning unit ensures that all equipment remains dust-free and operates under optimal conditions.
Gas Generation Module
At the core of the HyGGe™ 500P electrolyzer is the innovative HIFI™-powered Cell Stack, where water is split into hydrogen and oxygen. The Gas Generation Module integrates all components necessary to produce hydrogen at 30 barg under precisely controlled conditions.
The primary circuit, known as the demin water loop, circulates demineralized water through the Cell Stack. The resulting hydrogen and oxygen are separated in dedicated gas-liquid separators: purified hydrogen is directed downstream to the Gas Purification Module, while oxygen is safely released to the atmosphere.
Cell Stack
Exion Hydrogen’s proprietary PEM Cell Stack is designed to operate at a nominal pressure of 30 bar, producing 500 Nm³/h of hydrogen and 250 Nm³/h of oxygen. Each HyGGe™ 500P electrolyzer integrates one stack, delivering a nominal hydrogen output of 500 Nm³/h at 30 barg.
Exion Hydrogen’s HIFI™ technology is embedded in the stack, optimizing gas–liquid flow within the cells. This improves performance, reduces internal temperature gradients, and enhances overall stability. The result is smoother, continuous production with less mechanical stress, extending stack lifetime and lowering the Total Cost of Ownership (TCO).
By combining durability, safety, and performance, HIFI™ enables industries to scale green hydrogen production with confidence.
Gas Purification Module
The gas produced in the Gas Generation Module is further purified in two stages. First, a DeOxo vessel with a palladium catalyst on a ceramic carrier removes residual oxygen by bonding it with hydrogen in the gas stream. The exothermic reaction generates heat, causing the DeOxo vessel’s operating temperature to rise, which serves as an indicator of oxygen concentration. Next, the hydrogen passes through two dryer vessels filled with molecular sieve, which operate alternately for drying and regeneration. This process ensures a final hydrogen stream with a water content of no more than 2 ppm.
The panel of its Quality Control Module shows key safety and performance indicators, including gas purity and system output. A dedicated sensor monitors hydrogen levels in the oxygen flow to ensure they remain far below the explosive limit. For safety, the system provides an early warning if levels rise and automatically shuts down in a controlled manner if they approach a critical threshold.
Water Recycling Module
The Water Recycling Module drains excess water on the hydrogen side, using high efficiency gas water separation to minimize hydrogen loss to drain and combines it with the fresh demin water supply.
Water Purification System
The HyGGe™ 500P electrolyzer uses regular tap water as the feed source for hydrogen production. To prevent minerals and other impurities from entering the electrolysis process, the water is purified in several stages: a particle filter, an activated carbon filter, a reverse osmosis membrane, an electrodeionization unit, and finally a mixed bed. The by-product of this treatment remains clean water, but with an elevated mineral content.
Water purity is critical to both the performance and the lifetime of the cell stack. To further ensure purity, the demineralized water circulating through the stack is continuously passed over an ultrapure polishing bed.
Data Control Module
The Data Control Module is equipped with state-of-the-art PLC hardware designed to optimize performance and ensure secure operation. Its advanced process control system maximizes efficiency by leveraging frequency control units and supporting electronics, while a highly reliable safety layer continuously monitors and safeguards operations.
Power is supplied through an ATS (Automatic Transfer Switch) and UPS (Uninterruptible Power Supply) system, enabling controlled fallback into a safe state even in the event of a power outage. The control system is also remotely accessible via an intuitive graphical user interface, providing operators with full visibility and secure remote management.
Power Supply Container
A dedicated, purpose-built rectifier system is integrated into a standard 40-ft HighCube container. It combines proven rectifier modules from AEG with robust, maintenance-free transformers from Hitachi to create a 24-pulse rectification setup. A dedicated cooling system ensures reliable performance even under continuous high-power load conditions.
This configuration delivers ultra-low ripple DC current while minimizing disturbances to the customer’s MV AC power supply through low harmonics and a high load factor. All electronic components are housed in a sealed central compartment, ensuring they remain dust-free.
The HyGGe™ 500P electrolyzer features
| Nominal Flow: | 500 Nm³ per hour |
| Nominal Output Pressure: | 30 barg |
| Gas Quality: | > 4.8 (> 99,998%) |
| Containerized: | 45ft High Cube process container with same size top frame, and a 40ft High Cube Power Supply container. All standard sea freight containers. |
| Energy Consumption: | 5,2 kWh/Nm3 at nominal output |
| Turn Down Ratio: | 10% - 100% |
| Ramp time min-max: | < 1 min |
| Electrical Connection: | |
| Power supply container: | Medium Voltage connection of 3 x 6300V (or on customer specification) |
| Process container: | 3 x 400V Electrical IT Network |
| Nominal power consumption BOL: | 2,6 MW |
| Process Container (45ft HC): | 13,72 m x 2,44m x 2,90m - 25 ton |
| Rooftop Frame (45ft HC): | 13,72 m x 2,44m x 2,90m - 10 ton |
| DC Power Supply Container (40ft HC): | 12,19 m x 2,44m x 2,90m - 22 ton |