Structural Design and Analysis of a Hydraulic Frame for PEM stack: An Engineering Approach to Safe Uniform Stack Compression Green Hydrogen Systems

This book presents the design and structural analysis of a hydraulic compression support system developed for a Proton Exchange Membrane (PEM) electrolyzer stack. The system is designed to apply uniform, controllable compressive loads up to 75 tonne using a hydraulic jack and oil tank assembly mounted on a structural steel frame. Finite Element Analysis (FEA) was conducted to evaluate stress and deflection behaviour at different load cases. The results confirmed that the structure, fabricated with E250 grade steel, provides sufficient strength, stiffness, and safety for PEM stack compression applications. This study bridges the gap between laboratory-scale hydrogen research and industrial-scale mechanical design, offering a practical and cost-effective solution for future hydrogen energy systems.