Green hydrogen production is becoming essential as the world transitions to cleaner energy.  Its capacity to displace fossil fuels in several industries is resulting in the need for more extensive production.  Though increasing output has its drawbacks, including the need to improve efficiency, reduce prices, and create the necessary infrastructure.  And, to develop workable packages to utilize the true potential of green hydrogen one would need to enhance design, optimize workflows, that ensure the seamless use of renewable energy sources. To achieve this, one would require multidisciplinary technical experience & expertise. A specialist organization like Rishabh Engineering with multidiscipline design engineering services excellence can help offer crucial integration and support services to support their green hydrogen initiatives.

With this blog, let’s explore the key strategies for scaling production of green hydrogen, potential challenges in the process and how a multidisciplinary design engineering company can help.

The electrolysis process produces green hydrogen using renewable energy sources like solar, wind, and hydropower.  Furthermore, carbon is not released by this kind of hydrogen, in contrast to blue or gray hydrogen that comes from fossil fuels. The primary obstacle for electrolysis method for wider availability is about higher costs while boosting its efficiency and preparing it for large-scale applications.

• High Production Costs: This gas is more expensive to create than traditional fuels since it involves renewable energy and equipment like electrolyzers.
• Lack of Infrastructure: The poor infrastructure for its delivery and storage prevents it from being widely used.
• Energy Efficiency: Due to the high electricity consumption of electrolysis, it is imperative to find methods to increase process efficiency.
• Water Use: Using efficient water management strategies is crucial since the creation of green hydrogen requires a lot of freshwaters.
• Safety and Regulations: This inflammable gas must be handled cautiously and in compliance with specific regulations to avoid dangers.

Read this blog to explore the green hydrogen production challenges & solutions in detail and discuss how Rishabh Engineering can help.

To overcome these challenges, a comprehensive approach integrating multidisciplinary engineering expertise is essential. A key aspect of this is BoP and its seamless integration support provided by design engineering companies. Here are the critical strategies that can drive success:

1. Advancing Electrolyzer Technology

The efficiency of the chosen technology for scaling green hydrogen technology is crucial in reducing production costs. and therefore, improvements across materials, membrane technology, and system design are essential.

• Design Optimization: To increase efficiency, multidisciplinary teams work on cutting-edge materials including solid oxide and proton exchange membranes.
• Scale-up of Production Units: Design engineering companies concentrate on creating scalable and modular designs that facilitate mass production and lower costs.

2. Improving Storage and Transportation Solutions

Hydrogen storage and transport remain key bottlenecks in large-scale deployment.

• Development of Advanced Storage Solutions: Design engineering companies support with designing high-pressure tanks and liquid hydrogen storage systems.
• Pipeline Infrastructure Development: Multidisciplinary design engineering efforts contribute to pipeline material selection, compression technology, and safety compliance.
• BoP Support for Hydrogen Logistics: Design engineering teams help ensure efficient compression, storage, and distribution networks to facilitate hydrogen transportation.

3. Optimizing Water Management

Water is a crucial input in electrolysis, and sustainable sourcing is essential.

• Use of Seawater Electrolysis: Research is ongoing to enable direct electrolysis of seawater, eliminating freshwater dependency.
• Wastewater Recycling: Engineering teams design closed-loop systems to minimize water wastage in hydrogen plants.
• Balance of Plant (BoP) Integration: Design engineering companies design & integrate power distribution systems, cooling systems, and energy storage solutions for efficient plant operation. Additionally, it includes BoP Water Treatment Solutions, which involve the integration of advanced filtration, desalination, and recycling systems into the hydrogen plant.

4. Enhancing Process Safety and Regulatory Compliance

The flammable nature of this gas requires stringent safety protocols.

• Process Hazard Analysis (PHA): Multidiscipline Engineering teams conduct safety simulations to identify and mitigate risks.
• Regulatory Compliance Support: Experts ensure compliance with global hydrogen safety standards and environmental regulations.
• BoP Safety Engineering: Implementation of fire suppression systems, explosion-proof infrastructure, and risk mitigation strategies.

Learn more about the main elements of Hydrogen BoP, crucial design factors, and how they help ensure designing of effective, safe, and economical systems.

Design engineering companies help integrate multiple engineering disciplines, thus ensuring an efficient and cost-effective approach to green hydrogen production. BoP plays a crucial role in optimizing plant performance by integrating all auxiliary systems effectively.

Process Engineering

• Designs optimal electrolyzer configurations to enhance hydrogen yield.
• Develop BoP components such as cooling, ventilation, and gas handling systems.

Mechanical & Piping Engineering

• Develop safe and efficient hydrogen pipelines and storage solutions.
• Ensures robust material selection for high-pressure hydrogen systems.
• Designs and integrates BoP piping layouts and mechanical support systems.

Electrical & Instrumentation Engineering

• Designs power distribution systems for hydrogen plants.
• Implements automation for real-time monitoring and optimization.
• Develops BoP electrical layouts, instrumentation, and control systems.

Civil & Structural Engineering

• Plans and constructs scalable hydrogen production facilities.
• Develops robust foundations for high-pressure storage tanks and electrolysis units.
• Designs structural elements for BoP integration, ensuring stability and compliance.

Safety & Compliance Engineering

• Conducts risk assessments and fire safety simulations.
• Ensures adherence to ASME, IEC, and other global safety standards.
• Designs BoP fire protection, explosion prevention, and hazard mitigation solutions.

Our team has been instrumental to scale green hydrogen production projects with its multidisciplinary design engineering specialization, particularly in BoP integration.

We offer:

• End-to-End Engineering Support: From feasibility studies to detailed engineering and safety analysis.
• Advanced Safety & Compliance Services: Conducting fire & explosion risk analysis for hydrogen plants.
• Process Optimization & Cost Reduction: Enhancing electrolyzer design and plant efficiency.
• Comprehensive BoP Solutions: Designing and integrating power distribution, cooling, storage, and safety systems to optimize plant operations.

Real Life Case Study

Case Study:

Design & Engineering Integration With Balance of Plant for a Green Hydrogen Project

Client:

A global leader in solar PV modules and solar energy solutions

Project Description:

The client, an Asia-based global leader in solar PV modules and solar energy solutions, aimed to advance its green energy mission by establishing a 100 kW Hydrogen Manufacturing Unit. The unit was designed to produce 20 Nm³/hr of green hydrogen with 99.99% purity at 12 kg/cm²g. While the hydrogen production plant was supplied by the client, Rishabh Engineering was selected to design & engineer integration with balance of plant (BoP) for the green hydrogen project. The BoP scope included auxiliary systems and utilities crucial for ensuring operational efficiency, safety, and reliability of the hydrogen facility.

Scope of Work:

• Detailed engineering for the Balance of Plant (BoP) systems for the green hydrogen unit, including mechanical, piping, civil & structural, electrical, and instrumentation engineering.
• Design and integration of a fire protection system, compressed air system, and nitrogen cylinder bank into the overall utility framework.
• Development of design basis, process data sheets, control operating philosophy, master planning, hazardous area classification (HAC), and 3D modeling of the entire facility.
• Preparation of piping GAD & isometrics, electrical load list, single line diagram (SLD), civil design for equipment foundations, and complete instrumentation design.
• Bill of Quantities (BOQs), RFQs for all packages, and Technical Queries (TQ) along with Vendor Document Review (VDR) for procured packages.
• Integration of the Electrolyzer Unit from the technology supplier and ensuring compliance with renewable hybrid power integration (Solar + Wind).

Rishabh Engineering’s Solution:

A complete engineering solution for the smooth integration of BoP systems at the green hydrogen plant was provided by Rishabh Engineering team.  To increase hydrogen generation and minimize energy usage, the multidisciplinary team concentrated on improving the plant layout.  They ensured long-term operational efficiency by designing modular piping systems for scalability and ease of maintenance.  To stabilize electrolysis processes and guarantee continuous performance, the group also created a strong hybrid power management system.  Rishabh Engineering also made sure that the hydrogen filling and storage systems complied with all applicable safety regulations.  The Green Hydrogen BoP systems were successfully integrated by Rishabh Engineering by utilizing its experience, strengthening the client’s dedication to sustainability and renewable energy

The production of green hydrogen must rise to ensure a sustainable energy future.  Improving safety, integrating renewable energy, streamlining operations, and providing reliable infrastructure all demand a multidisciplinary engineering approach. Businesses like Rishabh Engineering work as a specialized green hydrogen engineering consultant to close technological gaps and develop relevant packages for hydrogen projects.. With detailed engineering expertise across process, mechanical, electrical, civil, and safety disciplines they can support successful deployment of large-scale green hydrogen facilities.  A global hydrogen economy is becoming a more realistic objective as costs come down and technology improves. Multidisciplinary technological capabilities will be invested in to maximize the potential of green hydrogen as a clean and sustainable energy source.

Our team with their multidisciplinary design expertise can help overcome the hurdles in scaling green hydrogen production.