Following Coffman’s design of the Nel Hydrogen 10-MW proton exchange membrane stack module (PSM), market signals indicated that future demand for electrolysis H₂ production would be at large scales, with minimum plant sizes of 100 MW being discussed by potential developers and utility owners.

Utilizing the PSM product, Coffman developed the design of an innovative 100-MW H₂ production facility with 10 PSMs as the central building block. The project included all required Balance of Plant (BoP) infrastructure, including water treatment, water oxygen management systems, H₂ gas management systems, process piping, chilling and cooling systems, power distribution, instrumentation and controls, and structural supports.

The plant design integrated various vendor equipment, with Coffman leading selections of the best solutions for this large-scale facility. Coffman designed and optimized the entire plant, including process design, control philosophy creation, basis of design development, equipment specification, vendor coordination, and 3D modeling.

The goal of the 100-MW facility design is to provide the market with a de-risked FEL-2 level design that can be further engineered and adapted to a customer’s specific project site and application. Coffman and Nel leveraged their combined electrolysis and engineering design knowledge to create a production facility design that meets client demands, has a market-leading cost, footprint, low integration risk, and high overall performance.