Digital Technologies

V. CONSTANTIN, Emerson, Bucharest, Romania

Hydrogen (H₂) has been around since the universe began, and it has been used industrially on a large scale since the early 20th century. These operations have been, for the most part, limited to ammonia production and oil refining, with each facility manufacturing its own gray H₂ by reforming the methane found in natural gas. In these applications, it was necessary as a chemical feedstock, and releasing the resulting carbon dioxide (CO₂) to the atmosphere was not closely monitored.

However, reforming is an energy-intensive process. A typical steam methane reformer (SMR), which is a major processing unit, consumes half as much natural gas for fuel as the amount it reforms, yet the bulk of H₂ produced today still uses this approach.

Today, things are changing quickly. H₂ is emerging as both a non-carbon intensive energy source and an energy storage mechanism that is useful for all manners of traditional applications, but also new highly sustainable products and processes, from steel production to fuel-cell vehicles. The question then becomes: Can we integrate existing production, along with new and emerging technologies, into one comprehensive value chain to maximize efficiency while also minimizing environmental effects?

Steps to link the chain. The first step is finding mechanisms to extend existing gray H₂ capacity, so those operations become links in the supply chain. Many may value being able to sell excess production, or they may need to purchase from others. In either case, the challenge of CO₂ emissions remains and must be addressed. SMR and similar reforming methods produce a stream of high-purity CO₂ from the carbon separation step, which is a prime candidate for carbon capture, use and storage (CCUS). If this can be added to the process, it becomes blue H₂, which is much higher on the environmental responsibility scale and necessary in any value chain. But it still uses a fossil fuel as the feedstock, and only a portion of the CO₂ can be captured.

Green H₂—made by electrolysis using renewable power—can be used for any purpose, replacing gray and blue H₂ in many applications if sufficient volumes are available. Electrolyzers are produced in many sizes, so they are easy to locate wherever there is sufficient renewable power infrastructure. Looking ahead, green H₂ can support energy security anywhere in the world since it does not depend on natural gas availability. It can also create the means for economic growth, as countless new jobs are emerging from its development.

However, while we understand its value, we are still in the early days of development. Compared to oil and natural gas distribution, available virtually anywhere on the planet, H₂ still tends to exist in limited pockets. To a distribution center wanting to use H₂ for powering its forklifts, or gas utilities providing H₂-blended gas to fuel consumer appliances, the question is: Where can I get H₂?

Similarly, a facility wanting to produce green H₂ must ask if there is a high-value application for what they are producing. In virtually any area, H₂ can be added to natural gas distribution, but this is a low-value option, both in profitability and positive environmental impact. It makes no environmental sense for gray or blue H₂ sources, but it is viable for surplus green H₂.

A better alternative, where there is an effective value chain, is for green H₂ producers to team up with chemical plants, stationary fuel cell power systems and vehicle operators. These types of applications have higher value and environmental impact, but the means must be available to make them possible, and transport over some distances may be required. This integration of production and use is rapidly emerging globally through private and government partnership to create industrial clusters or hubs.  

Comprehensive solutions for joining processes. The hydrocarbon value chain has been evolving for more than a century, but it was often dependent on a mix of manual and automated operations for production, storage and transportation. Today, sophisticated technologies are available to fully automate these processes, but they must be chosen and applied carefully.

The H₂ value chain will have some similarity to natural gas, but in many respects, the products are very different. The H₂ value chain will connect with various users that utilize it differently and likely with people who have little or no direct experience with it, so training will be of critical importance (FIG. 1).

So, what will this new value chain look like? It must cover three areas: 

1. Production. Whether green or blue, produced by electrolysis or through SMR with carbon capture, H₂ production requires robust control systems to ensure reliable, safe and seamless operations. 
2. Storage and transportation. The focus in this area must be on reliability and safety, using leak detection systems and other technologies to protect people, the environment and valuable H₂ resources. 
3. Distribution and end-use applications. Distribution will depend on rail and trucks, at least early on, but strategic pipelines should develop quickly. Automation products are available to support stationary and vehicle fuel cells, plus utility-scale power generation as turbines are newly manufactured or modified to burn a mix of natural gas and H₂, and eventually pure hydrogen. 

Meeting these objectives calls for a wide range of automation technologies and products, ideally purchased from a partner with domain expertise and experience in the process industries. The selected partner should have extensive experience in process and flow control, as well as safety and regulatory compliance, enabling it to work with end-users to develop and deploy these innovative technologies.  

The selected partner should be able to provide safety solutions and systems, as these are crucial in the types of industries where safety is a top priority. This includes technologies for emergency shutdown and safety instrumented systems, which are important in H₂ facilities. 

Ideally, the selected partner would also be able to provide: 

• Advanced process control (APC) solutions, including asset optimization software, because combining APC with basic process control systems will improve performance and efficiency by optimizing operations.  
• Instrumentation and measurement solutions, which in the context of H₂ production, are needed for monitoring and controlling process variables, such as pressure, temperature, flow, level and other parameters. 
• Control valves and accessories for use in H₂ production and distribution systems to control flows and ensure optimal performance.  
• Energy management solutions to help end-users optimize energy usage in H₂ production facilities, contributing to overall efficiency and sustainability. 

End-users can deploy these types of solutions to drive operational excellence, reduce production variability and ensure efficient production planning. These solutions are essential to accelerate the development of the H₂ value chain across all sectors and increase the efficiency of massive H₂ production plants.

If end-users and their vendor partners work together to address global energy challenges by linking an effective H₂ value chain, the transition to a cleaner, safer and more sustainable global energy ecosystem will accelerate.

About the author

Veronica Constantin, Vice President Global Sustainability at Emerson, is a 26-yr veteran of the company’s European operations. In her current role, Constantin leads the global sustainability strategy for Emerson, enabling customers to meet their environmental, sustainability and decarbonization goals. She joined Emerson in 1997, ascending through various roles, including Vice President for European strategic accounts, general management and sales. She earned an MS degree in electrical engineering from the Polytechnical University of Bucharest.