Fuel Cell Hoses for Machinery, Systems, and Vehicle Technology

Fuel cell hoses are an important component of fuel cell systems. They are also often referred to as hydrogen hoses. Fuel cells convert chemical energy, stored in a fuel such as hydrogen, directly into electrical energy. This process generates electricity, water, and heat. To enable these processes, various media and materials, such as fuel, oxygen, water, coolants, and electrolytes, must be directed into the fuel cell.

Fuel cell hoses play a crucial role in this, as they convey the various gases and liquids into and out of the fuel cell at the correct time and in the right quantities. Fuel cell hoses must meet particularly high demands, such as resistance to aggressive chemicals, high temperature stability, and flexibility.

In fuel cell powertrains, lines are required for thermal management, fuel supply, and air intake. Due to the specific operating conditions, these lines are flame-retardant and have a high electrical surface resistance. Efficient cooling of the fuel cell is an essential part of optimised thermal management for fuel cell vehicles.

Do you require fuel cell hoses for your projects in fuel cell technology? Book a non-binding consultation with our experts by clicking here or download our interactive product catalogue now for an insight into the NovaNox® fuel cell hose portfolio.

Fuel cell vehicles use electrical energy from hydrogen or a methanol-water mixture. This energy is generated using a fuel cell or a Direct Methanol Fuel Cell (DMFC) and is either used directly for propulsion or stored in a traction battery.

NovaNox® offers specially manufactured cooling water hoses, fuel cell hoses, hydrogen hoses, and air intake hoses for fuel cell systems and hydrogen engines. These hoses are non-flammable and exhibit electrical surface resistance. They can also be manufactured according to flammability class UL94-V-0 and are resistant to high-purity cooling water.

Thanks to our extensive experience in tank technology, we can also offer optimal and custom-made fuel tanks for e-fuels.

The Direct Methanol Fuel Cell (DMFC) uses a methanol-water mixture for electricity generation. Unlike conventional fuel cells, hydrogen does not need to be compressed under high pressure. Methanol is liquid at normal temperatures and pressures and is heated to approximately 300°C in a metallic reformer. In a catalyst, it is split into hydrogen (H), oxygen (O), and carbon dioxide (CO₂).

Carbon (C) and oxygen (O) are released into the environment as CO₂, while the energy of the hydrogen (H) is released. The generated electricity is either stored or fed directly to the vehicle's electric motor. A vehicle with a DMFC only emits climate gases, and this technology is already being used in maritime applications.

A vehicle with a methanol fuel cell combines the advantages of an electric vehicle and an internal combustion engine. Clean combustion occurs, with only as much CO₂ released as was needed for energy generation. However, the methanol must be produced climate-neutrally. Refuelling takes a similar amount of time to a classic internal combustion engine, while charging an electric motor takes much longer.

Methanol is classified as a hazardous chemical and therefore requires a sealed and secure fuel tank for storing the methanol-water mixture. NovaNox® offers tailor-made solutions for this challenge. The company has many years of experience in the production of fuel and industrial tanks and can manufacture steel, stainless steel, and aluminium tanks to meet your requirements. NovaNox® also supplies silicone hoses and fuel hoses, which are ideally suited for conveying methanol-water mixtures due to their resistance to acids, alkalis, and chemicals.

NovaNox® fuel cell hoses primarily consist of Ethylene Propylene Diene Monomer (EPDM) rubber. For applications with high positive or negative pressure, stainless steel wire reinforcement can optionally be incorporated. The hoses feature smooth inner surfaces for improved flow and can be used in a temperature range from -55°C to +200°C (briefly up to 220°C).

The EPDM material used makes the hoses flame-retardant and minimally conductive. The risk of contamination by extractable substances is minimised, and they contain very few volatile components. This protects the fuel cell from damage by foreign matter. The hoses are frequently used as cooling water hoses in fuel cell vehicles, as they are resistant to the glycol-water mixture used.

NovaNox® radiator hoses have been specially developed for use in fuel cell vehicles. They are made from high-quality materials such as VMQ (silicone rubber) or EPDM (Ethylene Propylene Diene Monomer rubber), which undergo rigorous quality checks. The hoses are manufactured using state-of-the-art technologies and meet high demands for temperature, chemical, and ageing resistance. The hoses can permanently withstand temperatures from -50°C to +220°C. For even higher temperatures, NovaNox® offers high-performance silicone that can withstand up to 250°C.

The hoses are also resistant to various chemicals, alkalis, and acids. They are impervious to weathering and do not degrade in quality over time. Furthermore, the hoses are highly elastic and can easily compensate for vibrations, braking, and tensile movements of the engine. The hoses have a low weight, contributing to vehicle weight reduction. NovaNox® radiator hoses are the ideal choice for fuel cell vehicles that demand high performance and reliability.

Fluorocarbon Rubber (FKM)

NovaNox® FKM hoses are highly sought after due to their excellent properties. Fluorocarbon rubber (FKM) is characterised by a temperature range of -20°C to 250°C. FKM exhibits good abrasion resistance and is compatible with acids, alcohols, oxygenated solvents, alkalis, fuels, hydrocarbons, and mineral oils.

These properties often make NovaNox® FKM hoses the preferred choice in applications where high resistance to chemicals and extreme temperatures is required. On request, NovaNox® manufactures fuel cell hoses with an inner layer of fluorocarbon rubber (FKM), as this abrasion-resistant and chemically resistant material is excellently suited for conveying high-purity hydrogen and coolants.

FDA-compliant Silicone

In addition to fuel cell hoses with an inner layer of fluorocarbon rubber (FKM), NovaNox® manufactures fuel cell hoses with an inner layer of FDA-compliant silicone.

FDA-compliant silicone hoses are hoses approved by the U.S. Food and Drug Administration (FDA) for use in the food and pharmaceutical industries. Some advantages of FDA-compliant silicone hoses include their high temperature resistance of up to 220°C and their flexibility. They are also odourless and tasteless and can be easily cleaned.

FDA-compliant silicone hoses are highly chemically resistant and withstand many chemicals such as acids and alkalis; NovaNox® FDA-compliant hoses also easily withstand high-purity hydrogen and coolants.

Vehicles that utilise fuel cells or direct methanol fuel cells for energy generation often feature compact designs. This means that manufacturers of fuel cell vehicles have limited space and require a bespoke hose solution. NovaNox® works closely with you to develop shaped hoses for your vehicles, boats, or ships. These shaped hoses are specifically tailored to your requirements profile and help you effectively utilise the available space. NovaNox® acts as a development partner, supporting you with new developments, further developments, and cost optimisations. With NovaNox® by your side, you can be confident that you will receive the best possible solution for your requirements.

Do you have a project with limited installation space? Then do not hesitate to click here and book your free and non-binding initial consultation with our experts. We will discuss your individual requirements together and develop a tailor-made solution for your installation situation.