tmax insulation solutions for hydrogen applications

Hydrogen is versatile. It is suitable for applications in power generation (electricity and heat), in the industrial sector as a process gas, or in mobility as a fuel or for power generation. Here, too, the intelligent solutions from tmax help to increase efficiency and protect components from excessive temperatures.

Decorative image for hydrogen

Our core mission:
Dealing with
high temperatures

tmax offers customized, intelligent solutions

tmax is already working on the technologies for tomorrow, making a significant contribution to decarbonization and a climate-friendly future. Our insulation solutions for fuel cells as well as for hydrogen combustion engines minimize heat losses, improve process efficiency and ensure full design flexibility. Our thin and lightweight insulating materials require minimal space in your hydrogen application. They are suitable for both simple and complex geometries.

tmax solutions are used for:

  • Fuel cells 
  • Hydrogen electrolysis
  • Reformers
  • Hydrogen combustion engines: turbochargers and exhaust systems
Folienisolierungen für den kompletten Abgasstrang am Beispiel eines LKW Motors
Foil insulation for the complete exhaust tract using the example of a truck engine

Contents in this e-book

How to overcome all challenges in the high temperature range.

Co-engineering for optimal hydrogen projects

Fast, cooperative, efficient

We provide comprehensive engineering services at every stage of your project. We supply pre-assembled fuel cells for large-scale production or complete insulation systems, including metal encapsulation. Whatever you need, we make sure you get the right solution.

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1. Engineering

Construction and design of insulating components + calculation.

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2. Prototyping

Rapid prototyping and prototype tools for customer requirements.

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3. Manufacturing

Cost-effective and flexible production for small and large series.

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4. Service

Do you have any questions? Our experts are always there for you.

Without insulation
Without insulation
With insulation
With insulation
Thermal simulation of an exhaust pipe without and with textile insulation.

3D simulations for hydrogen projects

Reduce development times and save costs

With our experienced research and development team, we have been developing prototypes for many years. Our extensive simulation methods provide important insights for the design of effective thermal insulation. This information leads to a significant increase in the efficiency of our solutions. At the same time, they reduce coordination loops and thus lead to the best possible solution, even more quickly. By producing hand samples, our customers can verify the simulation results directly on the test bench.

We offer comprehensive technical services at every stage of your project. In addition to engineering, we can provide high-quality prototypes, perform 3D scanning to capture geometries, are ready for volume production, and assemble or supply complete insulation systems, including metallic enclosures.

Unique in the industry: The tmax simulation solution saves you loops in the development process.

  • Find thermal weak points
  • Vibration simulation for predicting the behavior of a virtual component
  • Simulation for the evaluation of concepts and designs

In this way, even before a prototype is produced, we are able to find the most ideal design possible, taking into account the customer’s requirements.

Hydrogen applications with insulation needs

Along the hydrogen value chain, from production to transport to use, technical, temperature-related challenges arise in the various processes and applications. This is where tmax thermal insulation comes in.

They help to maintain the temperature within the system: On the one hand, heat losses are minimized. Thus, the efficiency in the stack or in hydrogen combustion engines can be increased. On the other hand, the heat radiation is avoided. In this way, temperature-sensitive surrounding components can be protected from heat. Our solutions also help to avoid possible explosion hazards. Thanks to our engineering know-how, insulation can be designed to minimize free volume.

In these hydrogen applications, tmax is already part of the value chain

Through electrolysis, water is broken down into hydrogen and oxygen, utilizing electricity. There are different procedures for this. High-temperature electrolysis (SOEC) in particular is characterized by high efficiency, but also high-temperature development.

In these processes, tmax high-temperature insulation ensures that temperature-sensitive components are protected from heat radiation and that the heat can be retained in the system. Our solutions help reduce heat loss and can thus increase the efficiency of the overall system.

Fuel cells convert a fuel (e.g., hydrogen) into electrical energy. Different methods can be used for this purpose. Fuel cells that mainly benefit from tmax solutions are the solid oxide fuel cell (SOFC) or the molten carbonate fuel cell (MCFC).

They operate in the high-temperature range from 650 °C to 1000 °C. With tmax high-temperature insulation, fuel cell stacks or the entire system (hotbox) can be insulated thermally efficiently. The high temperatures are thus safely controlled, surrounding components protected, heat losses avoided.

A hydrogen engine is an internal combustion engine that uses hydrogen as a fuel. It converts chemical energy into mechanical work and heat. Compared to the diesel engine, the exhaust gas temperature is lower in the hydrogen engine, which has a negative effect on its efficiency. Particularly in the lower engine speed range, the low exhaust enthalpy has a detrimental effect on turbocharging and correspondingly on engine dynamics.

Insulation of the manifold and turbocharger minimizes energy losses in the exhaust tract. The temperature is maintained in the system and helps to make charging and combustion more efficient. The result is increased efficiency of the hydrogen combustion engine, primarily in the lower load range, and a higher exhaust gas temperature, which has a positive effect on exhaust gas emissions.

Reformers are used to produce hydrogen from carbon-containing energy sources (e.g., natural gas) and water.

The reforming process takes place at temperatures between 500 °C and 600 °C.

In this process, the reduction of process heat is essential for the overall process efficiency and thus the effectiveness. This is precisely where the insulation solutions from tmax can provide significant added value. The process heat can be retained in the system, and surrounding components protected from the heat. In this way, compact construction methods can be realized.

Hydrogen: The future has a heat problem, tmax the solution

The world’s goal is ZERO CO₂ emissions.  The future is a mix of engines using different fuels. Hydrogen drives play a major role here. In the near future, production-ready engines will find their way into the mass market.

And tmax is a part of it,  with proven excellent results in increasing efficiency.

As the industry leader in intelligent insulation and insulating solutions for the hydrogen market, we increase the efficiency of hydrogen engines and turbochargers.

Hydrogen transporter
Decorative picture for hydrogen theme

tmax: innovative solutions for demanding hydrogen applications

Along the hydrogen value chain, from production to transport to use, technical, temperature-related challenges arise in the various processes and applications. This is exactly where thermal insulation from tmax comes in.

They help maintain the temperature in the system, which has two main positive effects:

On the one hand, heat losses are minimized, thus increasing the efficiency of e.g.,   hydrogen engines. On the other hand, heat radiation is avoided, protecting high-quality fuel cell systems and temperature-sensitive surrounding components from heat.

  • Marine

    SOLAS: Less heat. More safety.

    Market leader for SOLAS-compliant insulation in the marine sector for over 45 years.

  • Oil & Gas

    A prevented fire does not need to be extinguished

    100% SOLAS compliant insulation solutions for maximum work safety on your platform.

  • Power Generation

    Insulation technologies for stationary power generation.

    Undisputed technology leader for outstandingly effective thermal insulation.

  • Performance

    From prototype to series production.

    Insulations that were unthinkable yesterday are now ready for series production in the shortest possible time.