Articles
H2: Earth’s next great energy source?
H2 Equipment and Services
J. KAUFMAN, BelGAS, Newell, West Virginia
The quest for a sustainable, inexpensive, global green energy source is well-documented and ongoing. In recent years, hydrogen (H2) has emerged as a promising solution, with the potential to provide a steady supply of sustainable, clean-burning fuel.
Like all existing technologies taken for granted today, the earliest innovations were not possible until research and development (R&D) advanced them. In the future, we may look to H2 as a clean energy source, but there are still work and discoveries to be made.
Because H2 molecules are smaller than natural gas molecules, regulator technology must adapt to manage the load safely. The evolving science of regulatory technology is being examined, measured and validated to accelerate the adoption of H2 as a new energy source.
According to the Hydrogen Council, investment in H2 projects by 2030 will total $500 B. Some studies have shown that H2 can support one-quarter of the world’s energy needs by 2050. Greater investment will lower H2’s cost and create more opportunities. As these different opportunities are explored, we will truly discover the potential of H2 and how it can help decarbonize the world. For nations to meet their emissions reduction goals, H2 must play a significant role in the world’s energy future.
Smaller molecule, bigger challenge. The energy sector has been accustomed to the combustion engine and conventional gas transmission for decades, which may provide a head start on H2 transmission due to a fundamental understanding of energy derived from gaseous substances. H2 presents an opportunity to help decarbonize the world without a major shift in infrastructure. Blending H2 with natural gas safely will also contribute to carbon emissions reductions. However, we must also be aware of the limitations of the current infrastructure regarding H2 transmission.
One of the reasons for these limitations is that the H2 molecule is significantly smaller than the molecule of methane (CH4), the primary component of natural gas. Attempting a straight transfer of H2 into the existing natural gas infrastructure will result in excessive leaking and inefficient delivery. Regulators must be sealed tightly so the H2 gas does not leak. This is what the author’s company’s helium test bench is studying. H2 is also known to embrittle certain metallic materials under stress, so applications must be sensitive to material compatibility.
Proving ground: Testing the technology of tomorrow. R&D teams have something to prove—in this case, the potential role H2 might play as a future energy feed source. As such, an engineering team has developed an in-house helium test bench to check pressure regulators and other flow control devices for external leakage. Helium is used to test for H2 readiness because it is non-combustible and, therefore, easier to handle, and is a slightly smaller molecule than H2. If a pressure regulator can seal helium without leaking, it will seal H2.
The tabletop testing system uses an automated clamping system to attach the regulator in a fixture—the clamp seals along the inlet and outlet of the regulator to start the pressurized helium. A transparent enclosure is secured over the testing mechanism to contain potential leakage. Inside, a mass flowmeter detects even small amounts of helium leaks from the regulator. In addition, a high-precision helium sniffer can detect the leak’s location.
The ultimate goal is to provide internal certification, ensuring a given pressure regulator has passed helium testing for external leakage and is approved for use with H2. Because there is no International Organization for Standardization (ISO) or American National Standards Institute (ANSI) standards for such an application, this in-house certification can give peace of mind to end users that a pressure regulator is safe to use in H2 applications.
Testing began with a non-relieving gas and propane regulatora due to its smaller envelope and because a customer reported using that regulator to control the flow of 100% H2 for 18 yr with no problems. Testing will continue through the other regulators in the product line. This testing could also lead to the development of new products specifically designed for the H2 market, with diaphragms, assemblies, seals, O-rings and other components redesigned to meet application demands.
Burns clean, but expensive to cleanly produce. H2 has many benefits as an energy vector, not the least of which is that its only byproduct is water. It burns much cleaner than fossil fuels and leaves virtually no carbon footprint. Another advantage is that H2 is plentiful; in fact, it is the most common element on earth. However, it is always bound to another substance, meaning it must be separated before it is viable to use. This is why H2 is defined as an energy vector, not an energy source.
There are many methods for producing H2, each with pros and cons, but most methods used today require using an energy source that creates carbon. Those that do not are prohibitively expensive [although the U.S. Inflation Reduction Act (IRA) provides tax credits that will make American green H2 the cheapest in the world, as low as $0.73/kg], so separating H2 becomes a matter of compromise—choosing a production method that creates greenhouse gasses (GHGs) or a cleaner method that is much more expensive.
The most common method for H2 production is steam methane reforming (SMR), where steam and CH4 are combined with heat to yield H2. However, carbon dioxide (CO2) is produced in the reaction and must be captured to reduce the environmental impact. The production method of electrolysis uses electricity to produce H2 and can have a low environmental impact if the electricity is generated from renewable energy sources (e.g., solar, wind).
Selecting the best H2-producing technology depends on the application. Incorporating carbon capture, utilization and storage (CCUS) can reduce or eliminate the carbon footprint of H2 derived from separation powered by fossil fuels. In CCUS, carbon expended during the process is collected and can be used for various purposes, including as an additive for plastics and concrete, plant food, refrigerants or injection into wells for oil and gas recovery. It can also be stored in underground and above-ground facilities and abandoned oil and gas reservoirs.
Playing the percentages. A key question that must be answered is what H2 concentration level will be most viable for conversion into consumer energy. H2 produces less energy than the same volume of natural gas, so maximizing the percentage of H2 in any fuel blend is paramount.
Studies show that up to 20 vol% H2 can be blended into existing natural gas infrastructure without any issues affecting end users’ appliances. Globally, utility companies are experimenting with blends anywhere from 5%–30% H2 mixed into conventional gas.
It is worth mentioning that, in 2016, Northern Gas Networks of Leeds, England, conducted a feasibility study that found a conversion to 100% H2 using the gas network was technically possible and economically realistic. It is believed to be the first time standard gas operational procedures were tested under 100% H2 conditions on an existing network.
The differing proposed H2 percentages to blend into the current natural gas supply illustrate a challenge facing manufacturers of energy transmission equipment. Considering the H2 molecule is small and prone to escape from fittings and fixtures made for standard gas, the new standard must accommodate H2 at concentration levels somewhere between 5% and 100%. Which is to say, nothing has been determined at all.
The path to H2. The author’s company aims to engineer and produce pressure regulation products impervious to H2 leakage at the highest concentrations to maximize energy delivery for end users and service management for energy providers.
Investment from governments and private sources continually pours into the market, changing the landscape on an almost daily basis. As the list of global players grows, strategic partners must source suppliers who are experts in this rapidly evolving industry. Suppliers in the energy sector with a proven history of innovation, a deep knowledge base, a reputation for collaboration and high customer service values provide an edge in the market.
The scalability of H2 fuel solutions will require strict adherence to high standards of H2 protection and safe operation so the material transmits with no leakage and arrives at its destination without incident.
It is an exciting time to be in the energy field, as most agree we are on the cusp of H2 becoming the next great energy source. However, there is little consensus on how to make it viable, leaving it up to individuals and collectives to forge their paths. In many ways, we are writing the rules of the next energy landscape. The processes we experiment with and refine now may define energy protocols for generations.H2T
Notes
a BelGAS Type P38
About the author
JON KAUFMAN is the Business Unit Manager for BelGAS, a division of Marsh Bellofram. BelGAS is an originator in the design and manufacture of high- and low-pressure regulator products. Kaufman is responsible for all commercial aspects of BelGAS, ensuring consistent customer value with quality products at the right price and delivery time. He earned a BS degree in chemical engineering from Penn State, giving him unique insight into H2 at the molecular level. Kaufman’s understanding of the demands of H2 transmission and pressure regulation guides the company’s strategy. Prior to joining BelGAS, Kaufman spent 15 yr in design engineering and product management with a legacy company in the North American rail industry. In his spare time, he enjoys spending time with his wife and two children, golfing and working on projects around the house.
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