Whitepaper H2 Compression 2021-08-26
Whitepaper H2 Compression 2021-08-26
Whitepaper H2 Compression 2021-08-26
siemens-energy.com
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03 1. Introduction:
An element full of energy
05 2. The Ecosystem:
An interlocking value chain
08 3. Compression:
A crucial technology
12 4. The Future:
Balance requires diversity
Authors
Peter Adam
Siemens Energy,
Germany
Mark Barton
Siemens Energy,
United States
Keiren Lake
Siemens Energy,
United Kingdom
Michael Schulz
Siemens Energy,
Germany
Co-authors
José L. Gilarranz
Siemens Energy,
United States
Thomas Soulas
Siemens Energy,
United States
Help decarbonize
building heat
and power
Serve as renewable
H2
feedstock
Figure 3: Hydrogen can play different roles in the energy transition and is therefore an important lever for decarbonization9)
processes emits 5.6 percent5). Making a difference will require processes that emit ~ 10 ton of CO2 per ton of hydrogen
significant emission reductions across all these sectors. produced. However, two proven technologies for generat-
ing lower-CO2 emissions during hydrogen production are
That’s why hydrogen – the most common element in the ripe for further advancement:
universe6) – is such a focus of interest. It can support decar-
bonization in every one of these sectors. At the heart of • Green hydrogen is produced without generating any CO2
hydrogen’s appeal are three factors: by using electricity from renewable energy sources to
power the electrolysis of water, which results in hydrogen
• This element and its role in decarbonization are not theo- and oxygen. This is a key long-term source of clean hydro-
retical or ‘under development’. They are well known, well gen. In an electrolysis process 8 tons of Oxygen is produced
understood, and widely used. Hydrogen has played a role to make one ton of hydrogen. This Oxygen will probably be
in many industrial processes and industries for decades. used in future as well e.g. in Oxyfuel processes.
We know how to safely use, store, and transport it, and we
do this today with commercially available technologies. • Hydrogen also can be produced from natural gas, with
the resulting CO2 captured and stored so it does not end
• Existing proven technologies can produce hydrogen in up in the environment. This will be used as an intermedi-
several ways – some without releasing CO2 into the ate technology for the next decades to accelerate the
atmosphere. transition to a green hydrogen energy system long-term.
• Due to its versatility, hydrogen can play a variety of roles, A third zero-emission technology – using clean-ener-
including as an energy carrier for power generation and gy-powered pyrolysis to ‘crack’ natural gas into solid carbon
transportation, and as feedstock for industry, agricul- and hydrogen – is still in the development stage but offers
ture, and synfuels. great potential.
In addition, the market for hydrogen will grow dramatically As economies decarbonize and companies look for ways to
as the energy transition is inevitable and the need for lower the climate impact of their processes, hydrogen
decarbonization becomes more urgent. From approximately offers a tremendous opportunity. With proven technologies
75 Mtpa today, market demand is expected to rise up to ten set to become even more efficient, accompanied by addi-
times to 750 Mtpa 20507). Nearly all of today’s output is tional benefits through sector coupling, hydrogen can help
utilized to produce ammonia and other chemicals for indus- companies, industries and economies achieve both
try and fertilizer, and for refining. By 2050, the largest commercial and environmental goals.
shares will be used as a transportation fuel, as fuel for
industrial energy, for building heat and power, for power To make this possible, organizations require a partner with
generation, and for new and existing feedstock8). decades of experience across the entire hydrogen value
chain. Siemens Energy brings a unique constellation of
The way we produce hydrogen also will dramatically technologies and expertise to help business, industry, and
change as we move along the decarbonization pathway. society make the most of the hydrogen revolution at all
Currently, most hydrogen is produced from fossil fuels in stages – today, tomorrow, and in the long term.
A process with many components other. That’s already how it is done with today’s conven-
tional hydrogen production. Around the world, there are
While the possibilities for hydrogen are enormous, nearly 9,000 kilometers of hydrogen pipeline, some as long
unlocking this opportunity is only possible when all the as a couple of hundred kilometers linking production to
pieces of a fully integrated value chain are put in place. consumption. As a result, the technology for hydrogen
A successful hydrogen project requires a supportive and transport and storage is well understood and well devel-
carefully designed regulatory environment, sufficient oped. This includes the technology to store hydrogen in
renewable energy supply, the right hydrogen-production large underground formations, such as salt caverns.
technologies, suitable transport and storage infrastructure,
and end users for the clean hydrogen. What’s more, at End users for clean hydrogen can include ammonia and
every step in this value chain, it’s essential that operations methanol producers that currently use conventional
are as efficient as possible – both in terms of cost and in hydrogen as an input. By switching to clean hydrogen, they
terms of minimizing impact on the environment. can shrink their carbon footprint. Likewise, steel manufac-
turers and other high-temperature process industries can
Location, location, location use clean hydrogen fuel to significantly lower their emis-
sions, especially since high-temperature processes can’t be
Location is a top priority for making any hydrogen project electrified easily.
succeed. This includes placing electrolyzers close to the
source of clean energy, whether adjacent to wind farms Industrial processes also can transform hydrogen into
and PV plants, or even built into offshore wind turbine transport fuel for fields such as aviation, shipping, long-
platforms. A minimization of the distance between the distance rail, and heavy trucks.
energy source and the hydrogen production will bring
about a significant cost advantage. Another major end user group that can benefit from being
located near to clean hydrogen production facilities are
That said, efficiency in the system is further improved when gas-fired power plants that today can run on a fuel blend
hydrogen production and offtake are located near each that includes a small amount of hydrogen.
H2 transportation
Compressors
Long distance
pipelines
O2 and CO2
pipelines
Figure 6: The H2 economy is a systems play - an interaction of different technologies, solutions and stakeholders (excerpt of the hydrogen value chain)
An essential component of the hydrogen value chain is energy into pressure energy, and the return channel which
compression. It is needed to move, store, and use redirects the gas and prepares it to enter into the next
hydrogen. From the point at which hydrogen is produced to stage. For the case of the last stage, the stationary compo-
the point where it is consumed, different types of compres- nents will have a discharge volute following the diffuser
sion are required. This includes the gathering of hydrogen (there is no return channel). The pressure ratio that can be
produced by electrolyzers, steam methane or autothermal achieved by the machine is influenced by the size of the
reformers (SMRs/ATRs), sending hydrogen through short- impellers, the number of impellers, and the rotational
or long-distance pipelines, compressing hydrogen to the speed than can be achieved.
pressure levels required by vehicle fueling stations, lique-
faction for vessel transport facilities, and feeding it into gas Irrespective of the compression technology that is chosen,
turbines or other downstream and petrochemical processes. getting hydrogen gas to the required discharge pressure
level usually requires several stages. In reciprocating
In addition, CO2 compression is a critical element to enable machines, the piston speed, stroke length and bore size
blue hydrogen production and related CCUS (Carbon together determine compressor capacity, and the compres-
Capture Underground Storage). sion ratio is limited by the discharge gas temperature,
based on American Petroleum Institute (API) industry
Hydrogen has the lowest molecular weight of any sub‑ standards. In turbocompressors, one key factor to influence
stance and has a low density (one eighth that of natural the pressure ratio capability per compression stage is the
gas): this has important implications for compression, tip-speed of the impeller (a function of the impeller diam-
including the need for more energy and more compression eter and rotating speed), which is usually constrained by
stages to reach a given compression level. Its small molec- aerodynamic design limits, as well as mechanical and
ular size also results in some additional sealing challenges material strength limitations.
for compressors to minimize internal and external leakages
compared against the requirements when they handle Reciprocating compressors
natural gas.
Several factors go into the choice of a reciprocating
Compression process compressor, including valve lift, rotating speed, piston
speed, piston and packing ring, rider bands materials, and
There are two primary compression methods used for capacity controls.
hydrogen today, both of which have years of demonstrated
success in industrial applications. The first is positive Valves, rotation speed and pistons
displacement, most commonly applied by reciprocating
compressors using a piston to compress the gas. For these The compressor valve is perhaps the most crucial element
machines, hydrogen is drawn into the cylinder through the of the compressor, requiring a balance between reliability
suction inlet as the piston moves from outer-dead-center and efficiency. High lift, high efficiency valves can lead to
position to inner-dead-center; the piston then reverses valve ‘flutter’ which causes the valve sealing elements to
direction and compresses the gas contained in the cylinder. cycle many times per single stroke of the piston.
As the gas reaches discharge pressure, the discharge valves
open, allowing the gas to flow from the cylinder at higher
pressure, and then the process repeats.
Reciprocating compressors
Over 1,500 units in operation,
over 2 million horsepower in H2 rich services
This approach, achieved by increasing rotating speeds, For operators looking to deploy hydrogen compressors, the
requires additional considerations regarding the compressor most salient features include the facility’s footprint, capital
and the compressor train, in terms of technical feasibility costs, availability/reliability and operating expenses
and ensuring that the solution is cost effective and efficient. (including the cost of maintenance). Both compressor types
The evaluations need to include the proper balance in the can handle a broad range of application scenarios, with the
design among mechanical, material stress, aerodynamic and choice of technology based on economic tradeoffs and the
rotor-dynamic criteria, among others. Finally, especially specific requirements of each application, including
considering the increased speed requirements of the required flowrates, pressure ratios, use cases, footprint
compressor, the overall train architecture needs to be prop- limitations, use of dry or wet sealing, and whether the gas
erly evaluated to achieve the best overall solution. is 100 percent hydrogen or blended with natural gas.
Markets
• Downstream/process industries
• Refining
• Pipelines
Turbocompressors:
• Primarily applied with moderate/high volume flows
• Two well-referenced product lines, i.e. integrally
geared and single shaft compressors to optimize
compression solution with Turbocompressors
Figure 9: Main target of Siemens Energy compressors is to provide typical pipeline pressure ratio in a single casing
Molecular weight and efficiency used in situations where lower volumes, but higher pres-
sures are required. Reciprocating compressors also are
The most apparent differentiator between reciprocating better suited where part-load operations are anticipated.
and turbocompressors in the hydrogen context relates to its
low molecular weight. While reciprocating compressors can OPEX considerations
have an advantage with respect to efficiency and leakage
for low molecular weight gases such as hydrogen, several While the higher efficiency of reciprocating compressors
aspects (including those identified above) have to be makes them attractive from a power consumption perspec-
considered for a proper evaluation. tive, turbocompressors can usually run for longer times
without requiring maintenance, so they have an operating
Compressor stages expense benefit resulting from their longer maintenance
intervals. Furthermore, when the end user has a spare
For example, while turbocompressors may require more centrifugal compressor modular cartridge available, the
stages, the nature of turbocompressor designs is such that time to refurbish these types of machines is significantly
multiple stages handling large volumes of gas can be lower, reducing the time to bring the facility back online.
accommodated in machines that occupy a smaller footprint
than reciprocating compressors handling the same volumes Capacity control
of gas at similar pressure ratios. For reciprocating compres-
sors, more stages require more cylinders, given the Capacity control facilitates greater efficiency in power
temperature limits, while turbocompressors can increase tip consumption by enabling users to compress only as much
speed and wheel size. This also means turbocompressors hydrogen as is needed. With reciprocating compressors,
can deliver capital cost advantages in high-volume situa- this can be achieved with fixed volume clearance pockets
tions. within the compressor cylinder, suction valve unloaders to
reduce compressor capacity, and reverse suction-flow or
The efficiency advantage of reciprocating compressors may infinite-step capacity controls.
also be diminished at high flow volumes, given the increased
number of cylinders required with that technology. For both reciprocating and turbocompressors, variable
frequency drive (VFD) motors can be used to vary the
As a result, turbocompressors are more often applied in rotating speed of the compressor to adjust to capacity
high-volume flow situations requiring relatively lower demand.
pressure ratios. Reciprocating compressors are more often
Addressing climate change will require action across the Here, compressors represent a basic technology, as they are
entire economy and in most other areas of life. Siemens used for a safe and cost-effective hydrogen transport and
Energy is committed to providing solutions that benefit storage – an essential point for a smooth energy flow and
society as well as the economy. Building a low-carbon deployment. With a comprehensive portfolio of both recip-
energy system to achieve the goal of full decarbonization rocating and turbocompression solutions for use in
will entail a range of energy technologies, including both hydrogen applications, along with a global manufacturing
zero- and lower-carbon solutions. network, Siemens Energy is prepared to meet the growing
demand for future compression technology and to enable
During the energy transition, renewable energy solutions, customers to shift to a more efficient and sustainable
such as solar PV and wind, will play a major role, but so will future.
natural gas and synthetic fuels such as hydrogen. These
technologies are not in opposition, they will actually Just as the hydrogen economy requires many parties to
complement each other. work together, the larger energy transition requires
industry, government, citizens and other stakeholders to
As policymakers look to address climate change, while also come together to build an energy system that is advanta-
ensuring affordability and security of supply as demand geous – to the people of today and tomorrow, and to the
grows, they cannot choose one over the other. Many solu- planet. By balancing interests and leveraging a range of
tions are needed today and will continue to be a crucial energy solutions, the global community will be able to
part of the energy story for decades. Siemens Energy is well address the threat of climate change and create countless
placed to provide holistic, clean and safe solutions for the new opportunities.
emerging hydrogen economy, by offering all necessary
technologies, products, solutions and services along the
entire H2 value chain and its application fields.
Figure 10:
In the interplay of the various technologies, hydrogen compression plays an essential role for a safe and reliable energy flow in all areas of application
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