
Hydrogen horizons
Engineering solutions for large-scale electrolysis
Pedro Raposo
In the quest for sustainable energy solutions, green hydrogen stands out as a promising alternative. Achieving large-scale electrolysis comes with significant challenges, including high energy requirements, large investments, and the need for advanced infrastructure. By incorporating engineering strategies such as RAM (Reliability, Availability, Maintainability) studies, these hurdles can be addressed more effectively. Exploring innovative strategies and technological advancements, the feasibility and efficiency of large-scale green hydrogen production can be enhanced.
Large-scale Power-to-X and hydrogen projects represent a pinnacle of technological achievement and complexity. These endeavours involve aspects such as upscaling of proven technology to sizes that were never designed before, optimising fluctuations in renewable energy sources with high plant availability and stable end product outflow.
Addressing key challenges of large-scale Power-to-X and hydrogen projects
One of the primary challenges in this area is the high capital cost involved. The initial investment required for setting up electrolysis plants, sourcing renewable energy, and establishing long-term offtake and distribution infrastructure is substantial. This financial barrier often necessitates significant funding and support from both public and private sectors. Moreover, the long payback period associated with such investments can deter potential investors, making it crucial to demonstrate the long-term economic viability of these projects.
The availability and reliability of original equipment manufacturers (OEMs) to deliver complete electrolyser plants, including all components, are crucial for large scale hydrogen projects. OEMs are often tasked to provide both core electrolysis units and ancillary systems like compressors and storage tanks. However, delivering detailed plant specifications and customisations required for these ancillary systems is often at a late stage and can impact project timelines and introduce risks during startup and early operations.
The next face challenge is linked with integrating Balance of Plant (BOP) components, which include cooling systems, power supply units, and control systems, is crucial for the efficient operation of large-scale hydrogen projects. However, BOP integration is complicated by varying project-specific conditions and renewable energy fluctuations, such as those from solar and wind sources.
Safety in large-scale hydrogen projects involves integrating multidisciplinary aspects such as process safety, venting, and working environment considerations, ensuring buildings meet safety standards, implementing HVAC systems to prevent hazards, designing processes to minimise accident risks, installing venting systems to safely release hydrogen, and creating a safe, ergonomic environment for personnel.
Enhancing project success with RAM studies: a proactive approach to optimising availability and minimising risks
At AFRY, we recognise that optimal production depends on both technical performance and high availability. Traditional project designs often overlook specific availability needs, leading to overdesign or unnecessary risks during critical phases like startup and early operation. To address these challenges, we employ RAM studies. This approach delivers cost-effective solutions by optimising technical performance and availability within an acceptable risk framework. In the early phase of the project, our methodology includes:
– Plant-level availability risk assessment: To define availability and Overall Equipment Effectiveness (OEE) requirements, and conduct a high-level review to ensure they are realistic and achievable.
– System-level availability risk assessment: To develop a high-level RAM model to map the plant’s process flow and determine specific availability requirements for each subsystem.
By incorporating these RAM activities early in the design phase, we aim to minimise CAPEX and OPEX risks, safeguarding the project’s investment and operational goals. This proactive approach aligns with our clients’ operational excellence objectives and supports long-term sustainability and efficiency.
RAM verification
AFRY extends RAM analysis into subsequent project phases to ensure subsystem and equipment performance meets availability requirements, minimising design risks and ensuring accurate financial projections. Key activities include:
– Subsystem and equipment-level verification: Use detailed RAM models to map process flows and review subsystem availability performance.
– Iterative review and adjustment: Conduct iterative RAM modelling to address inefficiencies and improve availability.
The benefits for clients include reduced design risks, leading to a lower risk of costly design flaws; enhanced CAPEX and OPEX accuracy, resulting in more precise expenditure estimates, improved project reliability and efficiency, which helps meet reliability targets and reduce downtime.
Incorporating RAM verification before the Final Investment Decision (FID) provides a robust framework for managing project risks and costs, improving long-term success and sustainability. AFRY’s experience with reliability-related solutions demonstrates significant life cycle cost savings when operational availability is addressed early.
Energy demand between fuel types
