Goals

Tools to design and manage the 100% H₂ network

• Tools for modelling consumption and demand of the NG network. No tools are known for the 100% H₂ network.
• The H₂ storage systems in the Hydrogen Valleys yet to be determined in order to guarantee the H₂ supply.

Advanced tool to optimise the design and operating of the hydrogen gas distribution network including matching supply and demand. This tool will envisage the injection, transporting, compression, storage and consumption of H₂ gas. This tool will enable optimised 100% H₂ distribution networks to be designed, while always guaranteeing security of supply. The tool will allow Hydrogen Valleys to be modelled and tested, using the electrolyser production curves and H₂ demand curves of the customer, with different storage system configurations to cover the transition periods, in order to determine the sizes, technologies and optimum locations to guarantee security of supply.

Structural Integrity

• GN+‹20%H₂ distribution network: Knowledge of the performance of materials, components and equipment that form part of the NG network and up to 20% H₂. Sufficient knowledge is not available on 100% hydrogen, particularly regarding safety margins and defect sizes that the infrastructure can tolerate, or the level of conservatism (safety margins) provided by the design standards using safety factors.
• No numerical simulation tools to assess material compatibility with 100% H₂ are known.

• Better knowledge of the hydrogen embrittlement and crackling phenomenon and its relationship with the mechanical properties and microstructure of the network’s materials and components.
• Dynamic autoclave to assess the damage tolerance of the components of the distribution network operating with 100% H₂.
• Advanced numerical simulation tool to assess breaking loads and safety margins in components in H₂ environments.

100% H₂ pipelines

• Better understanding is needed of the mechanisms and mitigating the effects of hydrogen embrittlement (HE) in steels for pipelines for pure hydrogen distribution, for a safe infrastructure and to avoid unexpected failures under lower than design loads.
• Modern steels, such as X42 pipe optimised with a specific chemical composition and heat treatment could be an alternative. However, there is a lack of knowledge about how the chemical composition and heat treatments affect the microstructure of these steels and their resistance to hydrogen embrittlement.

• Better knowledge of the hydrogen embrittlement and crackling phenomenon and its relationship with the mechanical properties and microstructure.
• By means of thermodynamic studies, mechanical tests and exhaustive microstructural characterization, the necessary and crucial knowledge will be generated to understand the relationship between microstructure, heat treatment and the effect on the phases present in the material. This will allow advanced material technology to be developed with greater resistance to embrittlement and with a parallel reduction in costs and weights.
• New X42 pipe with chemical composition and heat treatment optimised for transporting 100% hydrogen up to 160 bar pressure at a competitive price.

100% H₂ Compressor

• Conventional compressors.
• Conventional leak detection (‹20% H₂)
• Compressors without ‘self-containment’.

• Oil-free compressor
• Implementation of pressurised crankcase: New reinforced design and sealing of the crankcase walls to provide greater strength and structural stability under high pressure.
• Development of magnetic coupling: This component ensures total airtightness, eliminating any possibility of leakage in the system. This technology goes beyond traditional sealing methods, marking a significant advance.
• Explosive Area Safety System: Integration of advanced monitoring and detection systems to identify deviations in gas pressure or temperature demonstrates a concern for safety in critical environments.
• Self-containment: Solutions within a container in a classified area, dilution and ventilation of the container, calculate exhaust sources, mounting and anchoring.
• 100% H₂ Compressor which will allow the 4-bar up to 30-33 bar compression capacity to be demonstrated, within the H₂ flow range between 10-15 Nm3/h.

100% H₂ Boiler

• Boiler conversion kit up to 20% H₂.
• Only boiler company advertising a 100% H₂ boiler (BAXI). Lack of knowledge of the system used and the performance achieved by that boiler.
• Very limited information on solutions offered by competitors. In principle, systems based on pre-mix combustion technology as well as UV safety sensors.
• High CAPEX and OPEX.

• New conversion kit for a boiler with a BeeEngine combustion system to 100% H₂.
• Lower CAPEX: The cost of the system to be developed and validated will be lower than that of our customers, with an estimated saving of 20%.
• Lower OPEX: Given the simplicity of the system to be developed and validated, both in terms of type and quantity of sensors needed for the 100% H₂ boiler to operate properly, the maintenance deemed necessary will mean a saving of 30% for the end user (the system’s maintenance is streamlined, thus shortening the length of time involved + lower cost of the components as the sensors are less expensive).

H₂ Transmitter

• Catalytic sensor with significant limitations, such as catalytic poisoning with substances able to inhibit detection and even deteriorate the sensor (Type I).
• Limitations in the detection signal. A decrease in the detection signal is observed from a certain H₂ concentration above the LEL (lower explosive limit). This misreading can be interpreted as a total absence of combustible gas, when in practice it can be a potentially dangerous atmosphere. (Type II)    

• New developments capable of exceeding the limits of current prevailing technology (catalytic).
• Specificity: detectors capable of discriminating and detecting H₂ in particular, since catalytic sensors react to a multitude of compounds causing false alarms.
• Development of a sensor with MPS (Molecular Property Spectrometer, Type I) technology.
• Detection at high concentrations above 100% LEL (which can even reach 100 % v/v) and in environments with the absence of O2 by using thermal conductivity sensors (Type II).
• In both cases, the aim is to avoid poisoning (deterioration) as well as the main constraints of catalytic technology.

Advanced methodologies for the transition to the use of H₂ in industrial decarbonisation

• There is some research and real-world application examples for certain sectors, but more development and testing are still needed to move towards more widespread and effective application.
• Prospective analysis to identify H₂ potential for the decarbonization of the industrial sector is an emerging research topic. There are some studies and pilot projects that are exploring decarbonisation technology options, but more real-world research and testing is still needed to determine the specific role of H₂-associated technologies.

The developments will be validated through a case study on the regional energy system of the Basque Country (CALCINOR), with special emphasis on the decarbonisation of the industrial sector and the role of H₂.
• Development of ad-hoc prospective models and industrial decarbonisation roadmaps where the role of H₂ is evaluated.

100% H₂ distribution network

• Blending distribution and transport networks (natural gas with <20% H₂).
• Natural gas distribution demonstrator up to 20% H₂ (H2SAREA) and ‘Full Scale Test Setup’ demonstrator of the European Pipeline Research Group (EPRG) – > system that does not allow the continuous flow of fluids through the autoclave.

Distribution network design

• Lack of information on configurations to optimise their safe running and operating.
• Emerging information on measurement systems, but it is unknown which systems are better from a technical-economic point of view according to the measurement flow and pressure.
• The type of joints that can be installed in the flanges of hydrogen networks has not been studied.

• H2BIDEA Solution: 100% hydrogen gas distribution network, including key aspects such as transporting, compression and localised storage, measurement, configurations and safety and operability.
• H₂TestLab demonstrator to assess developments in real operating conditions (up to 30 bar with 100% H₂) and with a dynamic autoclave for 100% H₂.
• 100% H₂ distribution network.
• Conducting an experimental campaign in the H₂TESTLAB demonstrator to determine the performance of the network and its elements when operating with 100% H₂ when it is stored and re-injected into the distribution network to match supply and demand.
• The data obtained in these experiments will allow the validation of the developed software tool.
• Research and test different configurations of the distribution network to be able to guarantee the correct operation of the latter.
• Research and test different configurations of receptor facilities, in order to be able to define a standard configuration, with their associated safety systems and measurement & regulation systems.
• Research the design of hydrogen distribution networks so that they can be sectioned and perform vacuum operations.

Regulatory frameworks and procedures of the 100% H₂ distribution network

• There are no rules or regulations that determine the configuration of customer facilities and how to measure their consumption.
• There are no regulations for the construction of customer receptor facilities.
• The procedures do not allow certain operations to be performed when the network is under load.
• There are no specific procedures, equipment and accessories available to carry out operations under load with networks distributing 100% H₂.

• Research and test the different operating procedures of 100% H₂ distribution networks in order to work in safety (H₂TestLab).
• Research regulations and standards applicable to Hot Tap operations on hydrogen lines.