Today, we often associate hydrogen with climate protection and green energy – but not necessarily with welding and cutting. Yet hydrogen also makes an important contribution to environmental protection and occupational safety while delivering superior performance in many applications. With its HyCut fuel gas, Messer combines an innovative product with the specialized expertise needed for the optimal use of hydrogen in oxyfuel applications.
Reinventing hydrogen technology
Hydrogen was already used for metalworking more than 100 years ago, during the early days of welding technology. However, it was soon replaced by acetylene, which at the time was easier to produce and handle. Hydrogen has enjoyed renewed interest in recent years because its combustion doesn’t produce any CO₂. “In order to use hydrogen successfully for cutting and in other oxyfuel processes, the equipment had to be significantly redesigned,” explains Dr. Bernd Hildebrandt, Messer’s expert in thermal cutting. “This technology was pioneered through a collaborative development effort involving Messer Cutting Systems and one of our customers.” Among other products, this customer manufactures pipe components, large-diameter pipes, and monopiles for offshore wind turbines. As part of its commitment to environmental transformation, the company sought to play an active role in making cutting and welding more environmentally friendly.
Gas, expertise and consulting
Over a period of more than two years, the three partners optimized every aspect of the hydrogen cutting process. Among other innovations, cutting torches and nozzles were specifically engineered for use with hydrogen.
“In this sense, HyCut is much more than just a gas,” says Dr. Hildebrandt. “It is a complete solution backed by comprehensive expertise in the technology and its applications. This naturally includes customized technical consulting tailored to each customer's specific requirements.” In recent months, Dr. Hildebrandt has visited numerous metal fabrication companies to answer the many questions surrounding the use of hydrogen. “There are still some long-standing misconceptions and outdated assumptions – for example, about heat input and safety. In reality, however, hydrogen performs at least as well as acetylene or propane and, in most cases, is clearly superior.”
Measurable improvements and enhanced safety
The environmental benefits begin, of course, with emissions. Emissions are reduced not only because HyCut produces no CO₂ during combustion, but also because it generates significantly lower levels of nitrogen oxides (NOₓ) and fine particulate matter. Moreover, torch noise is approximately 5 dBA quieter – a substantial reduction. “For the people working with the torches, these are tangible and measurable improvements in occupational health and safety,” emphasizes Dr. Hildebrandt. “At the same time, companies can significantly reduce the emissions associated with the process.”
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| HyCut as compared with propane and acetylene (Source: Leibniz Universität Hannover) | |
Compared to acetylene or other fuel gases, the use of hydrogen is safer: The ignition temperature of hydrogen (560 degrees Celsius) is higher than that of conventional fuel gases. Additionally, a flammable mixture of fuel gas and air only forms when the hydrogen concentration reaches four percent. It also provides rapid preheating and more concentrated heat input, enabling faster piercing and higher cutting speeds. At the same time, the nozzles achieve a longer service life when used with hydrogen.
In practice, the unique properties of hydrogen also allow higher gas flow rates from a single cylinder. As a result, a single cylinder is often sufficient to supply even larger torches. These advantages are equally beneficial when using HyCut for soldering, heating, or flame straightening applications. “Additional benefits during cutting include noticeably smoother cut edges and easier slag removal,” adds Dr. Hildebrandt. “This means that significantly less finishing work is required.”
For more than 125 years, Messer, the today’s world's largest privately owned company for industrial gases, medical gases, specialty gases, and gases for electronics, committed to its guiding principles of safety, focus on customers and employees, responsibility for our society, sustainability, trust, and respect. Messer's Gases for Life and patented gas applications are essential for environmental protection, climate protection, decarbonization, and innovation.
