Application and Research Progress of Mechanical Hydrogen Compressors in Hydrogen Refueling Stations: Structure, Performance, and Challenges

Abstract

The hydrogen energy industry is rapidly developing, positioning hydrogen refueling stations (HRSs) as critical infrastructure for hydrogen fuel cell vehicles. Within these stations, hydrogen compressors serve as the core equipment, whose performance and reliability directly determine the overall system’s economy and safety. This article systematically reviews the working principles, structural features, and application status of mechanical hydrogen compressors with a focus on three prominent types based on reciprocating motion principles: the diaphragm compressor, the hydraulically driven piston compressor, and the ionic liquid compressor. The study provides a detailed analysis of performance bottlenecks, material challenges, thermal management issues, and volumetric efficiency loss mechanisms for each compressor type. Furthermore, it summarizes recent technical optimizations and innovations. Finally, the paper identifies current research gaps, particularly in reliability, hydrogen embrittlement, and intelligent control under high-temperature and high-pressure conditions. It also proposes future technology development pathways and standardization recommendations, aiming to serve as a reference for further R&D and the industrialization of hydrogen compression technology.