Green Hydrogen Inherent Safety Practices on large Industrial Scale

To meet the CO 2 emission reduction goals from the Climate Agreement, we need large-scale
production of green hydrogen through water electrolysis. Hydrogen plays a key role in the future
energy system as an energy carrier and storage of green energy. Furthermore, it will serve as
feedstock for climate-neutral industrial processes. In the process industry safety aspects of fossil-
based hydrogen production is well-known, but there is limited experience with large-scale water
electrolysis. The Institute for Sustainable Process Technology(ISPT) and the consortium partners
HyCC, Ørsted, Shell, Yara, DNV, RHDHV and TNO initiated a new project: Green Hydrogen Inherent
Safety Practices on large industrial scale. This project will increase awareness of safety for large
industrial scale water electrolysis plants. After all, industry, authorities, and society want zero
incidents.

The knowledge gap

Today electrolyser suppliers, operators, and owners have limited operating experience with safety
aspects related to large scale water electrolysis installations. Only small-scale installations exist
whereas these large-scale installations are becoming reality soon. Therefore, all partners wish to
further advance all related safety aspects and develop a uniform safety approach for large-scale
water electrolysis plants. One question is, for example, how to objectively assess scenarios with
exceptionally low probability and high potential consequences (black swans) and how to determine
cost-effective safety measures to address these. Therefore, there is a need to further develop joint
safety practices and guidelines based on credible scenarios for large-scale plants. It is also important
to communicate about safety risks transparently.

The project aim

In this project, we want to deepen the understanding of the potential risks of explosions due to
mixtures of hydrogen and oxygen in electrolysis equipment. The tools, methods, and data for
assessments of these risks, which typically have a low chance of occurrence but may have severe
consequences, will be investigated. The project provides credible scenarios and facts on the
fundamentals of explosions and the validity of detonation.
The focus is on an objective risk assessment methodology regarding fire and explosion risks with
oxygen and hydrogen mixtures in equipment. The development of consistent assessment methods
covers failure frequencies and consequences, including data on delayed ignition and detonation,
leading to corresponding safeguarding and appropriate safety distances.

Developing safe water electrolysis

Based on these insights, the project team compiles best practices for inherently safe design and
guidance for hazard assessment and risk mitigation. The project will also deliver a roadmap to
validate the findings with experimental data.

ISPT is the overall coordinator and will execute the project with DNV, RHDHV and TNO. All topics will
be explored together with the experts from industrial partners HyCC, Ørsted, Shell and Yara This
project is co-funded by TKI-Energy & Industry of the Dutch Ministry of Economic Affairs and Climate
Policy.

Safety Delta Nederland supports this project and is a very important party for connecting to
other H2-safety projects and knowledge.