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1、UNLOCKING THE HYDROGEN AGE Engineering challenges in the hydrogen value chainCONTENTSEXECUTIVE SUMMARYGREEN HYDROGEN INDUSTRY OVERVIEW KEY ENGINEERING CHALLENGES 478ADDRESSING CHALLENGES THROUGH DIGITAL ENGINEERING10CONCLUSION17EXECUTIVE SUMMARYGreen or low-carbon hydrogen is starting to receive att
2、ention from a wide range of businesses as a potential new energy source.Rapid changes in the global economic climate,fueled by pressures like decarbonization,decentralization,and digitalization,have spurred innovation within the energy sector and amongst heavy energy users,especially transport and i
3、ndustry.Organizations worldwide are implementing new energy models,based around electrification,alternative energy sources such as green hydrogen and biofuels,hydrogen for thermal engines,renewable energies for electrolysis,other technologies than electrolysis such as biomass thermolysis,and transpo
4、rtation of hydrogen via pipelines,trailers,decentralized energy,and platforms that enable peer-to-peer energy sharing.Hydrogen will play an essential role in all these changes.It is an energy-dense fuel that could replace oil and gas as an energy source,especially in hard-to-electrify transport and
5、industrial processes.Right now,most hydrogen is produced from natural gas;green hydrogen is the exception and is produced by the electrolysis of water powered by renewable energy.In the IEAs model for Net Zero Emissions by 2050,hydrogen and hydrogen-based fuels meet 10%of global final energy demand
6、in 2050,by which time demand will have multiplied almost sixfold to reach 530 Mt,half of which will come from industry and transport1.This will need to be mostly,if not all,green hydrogen currently,only 0.49 Mt is produced by electrolysis2.The entire world would therefore gain from an efficient,econ
7、omically sustainable green hydrogen ecosystem.But obstacles must be surmounted to reach these ambitious goals and reap their benefits.Much of the supply chain is still being developed since green hydrogen is still very much in its infancy.Efficiency,deterioration,durability,resilience,density,and el
8、ectrical power capacity are all issues that need to be addressed for the industry to be successful.To assess,maintain,and maximize efficiency,green hydrogen will need significant infrastructure investment,including Intelligent Industry-friendly digital infrastructure and advanced digital engineering
9、.Technology players will be strategically important to optimizing the low carbon/green hydrogen supply chain and preparing for a safe and secure environment.Innovative ideas and best practices discovered by others must be comprehensively applied to strengthen the resilience and dependability of the
10、hydrogen value chain.This whitepaper explores critical engineering challenges vital to creating a low carbon hydrogen value chain and explores innovative concepts to surmount them.Hydrogen will play an essential role in all these changes.4Unlocking the Hydrogen Age56Unlocking the Hydrogen AgeGREEN H
11、YDROGEN INDUSTRY OVERVIEW Key Insights Hydrogen is significantly more efficient than other fuel sources today and has a wide range of industrial uses,including refining,petrochemicals,and steel manufacturing.Green hydrogen ensures that Sustainable Development Goals(SDGs)targets such as cheap,renewab
12、le energy and resilient infrastructure are met,as well as supporting innovation.Declining costs of both decarbonized electricity and electrolysis technology will reduce the cost of producing green hydrogen.The worldwide green hydrogen market is estimated to reach$89.18 billion by 2030,with a CAGR of
13、 54%.This is mainly due to increased demand for on-site electrolysis setups from the industrial sector.Only 0.1%of the hydrogen produced worldwide is green hydrogen,which is created using renewable energy.Europe is the market leader in green hydrogen3.Only 0.1%of the hydrogen produced worldwide is g
14、reen hydrogen,which is created using renewable energy.7Companies producing green hydrogen and their supply chain will need to overcome significant engineering challenges to succeed in its large-scale commercialization and deployment:1.Plant design and return on investment2.Storage of hydrogen3.Trans
15、port and distribution of hydrogen4.Integration of hydrogen in the development of Smart Grids5.Developing hydrogen internal combustion engines 6.Enabling low-cost and sustainable fuel cellsAlthough scaling up green hydrogen presents difficulties,contemporary digital technology and digital engineering
16、 hold many answers.Digital engineering such as digital twins,prediction models,in particular,will be crucial in finding the path to a low-carbon economy.In the rest of the paper,we demonstrate the role digital engineering plays in overcoming these challenges and explore the complexity of its applica
17、tion.KEY ENGINEERING CHALLENGES8Unlocking the Hydrogen Age9ADDRESSING CHALLENGES THROUGH DIGITAL ENGINEERING1.Using digital models to improve plant design and ROITo meet market demand,businesses must scale up and enhance their green hydrogen plant designs.Addressing the design limitations of green h
18、ydrogen plants,the cost of alternative energy to power them,the price of desalination of water for electrolysis,and the sizing of equipment needs attention4.However,converting electrical energy into hydrogen via electrolysis is a rapidly advancing technology.Consequently,improving plant designs and
19、end-to-end green hydrogen systems can be costly and complicated due to a lack of market data and maturity5.Digital models that simulate the operation of different technologies involved in the industrial hydrogen chain can predict the performance and costs associated with plant development and offer
20、a promising route forward6.These models inform techno-economic studies that explore different scenarios to find attractive hydrogen plant cost models7.Building more powerful modelsCapgemini Engineering,in the framework of the SISTER(Innovative Solution for Renewable Energies Storage)project,is devel
21、oping a numerical tool that follows a systemic approach called THySO(Tool for Hydrogen System Optimization)that simulates the industrial hydrogen chain and considers performance,safety,cost,and environmental impact.An advantage of the THySO approach is its versatility:it can be tailored to various u
22、se cases due to a vast library of models.Figure 1 Example of evaluation of a Power-to-Gas-to-Power scenario using the THySO tool developed10Unlocking the Hydrogen AgeWhile these economic considerations are critical,models must go further.One of the fundamental challenges of modeling the industrial h
23、ydrogen chain is the sizing of all or part of the components required in this chain according to the energy demand and the energy production capacity.In addition,models must consider the environmental impact of the hydrogen chain,such as global warming,fine particle emissions,water acidification,and
24、 eutrophication,which should all be investigated as part of the Life Cycle Assessment(LCA)of the industrial hydrogen chain8.Finally,massive green hydrogen plants are also being constructed inside already-existing industrial areas.This imposes additional restrictions on design to ensure that ongoing
25、operations do not interfere with industrial green hydrogen production.So,the safety of installations using hydrogen has to be integrated into the modeling process,for instance,by simulating the risks of leakage or explosion.2.Designing hydrogen storage tanksDifferent hydrogen storage technologies ha
26、ve different Technology Readiness Levels(TRLs),and the usefulness of one solution over another depends on several criteria such as sizing,stationary or mobile application,duration of storage,density vs.volumetry,and environmental conditions.Compressed hydrogen as storage needs a large amount of ener
27、gy to reach high-pressure values due to its low volumetric energy density.Liquid hydrogen tank materials aim to minimize heat exchange with the surrounding environment but are not made to sustain high internal pressures.However,the bigger issue is the energy to convert gas.As the liquid impacts the
28、effectiveness and thus,the price.Along with that safety is also a big concern at high pressure.In the case of solid hydrogen storage,lightness,high option capacity,quick sorption kinetics,strong thermodynamic stability,and good cyclability are desired features for storage materials,and they must als
29、o be reasonably priced.Solid storage offers a wide range of material and design options-carbonaceous porous nano-materials,metal-organic frameworks(MOFs)9,covalent organic frameworks,complicated chemical hydrides,clathrates,amides,zeolites,and metal or intermetallic hydrides are the principal materi
30、als used.The choice of storage materials can impose restrictions like low gravimetric storage density(typically less than 10 wt%),poor reversibility,and low energy efficiency due to the substantial heat exchange that can occur during tank filling and emptying cycles.Storage of hydrogen as a solid mu
31、st also consider concerns around temperature and pressure limits.Other factors include aspects of design,legal issues,societal problems,and high costs.The durability of low-storage materials like fiber,metals,and polymers,and the potential for chemical reactions raise safety issues.Exploring this co
32、mplex design space is best done digitally.Exploring solid hydrogen storage options digitally For the construction of a solid hydrogen storage tank that achieves both productive energy efficiency and sustainable storage capacity,Capgemini Engineering is working on creating a numerical tool that deter
33、mines the optimal materials.A finite element model is being used to study sustainable and renewable alternative fibers for use in high-pressure vessels as a replacement for the conventional carbon fiber reinforced epoxy composite.Alternative fibres like basalt,E-glass,flax,and recycled carbon have b
34、een investigated for replacement.Lower burst pressures are the consequence,and none of the other composites can withstand the 1400 bar minimum pressure requirement.Hybrid vessels incorporating T700S carbon fibres and alternative fibres are suggested to increase the physical,environmental,and financi
35、al performances in accordance with storage pressure and mechanical requirements.Increasing economic,the E-glass/T700S carbon hybrid vessel and E-glass vessel for 700 and 350 bar,respectively,are the best vessels.For a 700-bar storage,basalt/T700S carbon and E-glass are the best fibres in terms of en
36、vironmental impact.Although T700S carbon/flax fibre composite looks to be more effective at 350 bar,T700S carbon composite remains the best contender for a 700-bar storage when it comes to vessel bulk.113.Transporting liquid hydrogen for distributionThe current hydrogen transportation pipeline infra
37、structure is insufficient to fulfill future demand.Existing natural gas pipes cannot be used directly for hydrogen due to embrittlement.Even combining hydrogen with natural gas at a 6 percent concentration by volume has a substantial impact on pipeline life.As hydrogen blending increases,the average
38、 calorific content of the blended gas falls,and thus an increased volume of blended gas must be consumed to meet the same energy needs.For instance,a 5%blending by volume of hydrogen would only displace 1.6%of natural gas demand.And this percentage changes with norms specified by the country10.When
39、high-volume transmission via pipes is impossible,hydrogen is often transported as a liquid.Transporting liquid hydrogen has two main challenges:“Boil-off”(i.e.,the evaporation of cryogenic liquid fluid in the tanks,including an increase in pressure and deterioration of the quality of the gas)and“Slo
40、shing”(i.e.,fluid movement in the tanks that causes damage,risk of leakage,etc)11.This represents a double challenge in the digital engineering process because the two physical phenomena are linked and must be integrated into a single dynamic calculation model in the design of an optimized cryogenic
41、 tank that is both durable and secure.In addition,to accurately predict the consequences associated with the release of liquid hydrogen from the pressurized tank,complex physical phenomena such as flash boiling,air condensation,or liquid jet impingement need to be considered in the model.Furthermore
42、,a certain quantity of hydrogen will be lost by evaporation,or“boil off,”of liquid hydrogen,particularly when employing small tanks with high surface-to-volume ratios.Finally,an analysis of the risks associated with the use of liquid hydrogen must be made and addressed,given the potential to damage
43、adjacent equipment and structures,and the possibilities of detonation due to leakage,among others.When high-volume transmission via pipes is impossible,hydrogen is often transported as a liquid.Modeling Hydrogen TransportationCapgemini Engineering Thermal&Fluid team is actively researching these cha
44、llenges and has developed new computational fluid dynamics(CFD)methods that can model complex flows as part of the Research and Innovation Project SIM4ENERGIES(Simulation for Energetics,dedicated tools and coupling strategies to address multi-physics problems).12Unlocking the Hydrogen Age4.Integrati
45、on of hydrogen in the development of Smart GridHydrogen can store and carry a vast quantity of energy.When transforming renewable electricity into an energy carrier for use in transportation and industry,hydrogen ecosystems provide a safe,adaptable,and environmentally friendly alternative.As an ener
46、gy source,a storage medium,and a clean fuel,hydrogen has a significant role to play in the development of the Smart Grid12.Hydrogens capacity to reach and integrate each area of the energy system enables renewable energy sources to be deployed and adopted to a far wider degree.Using contractual obli
47、gations,origin assurances,energy storage supplementary services for managing renewables in electricity networks,and direct blending with renewable power sources,hydrogen systems can be integrated into the electrical grid.Again,understanding the range of options and operating models is best undertake
48、n digitally.Capgemini Engineering is working with ENIT,leader of the MOSAHyC consortium,to develop Smart Grid experimental models to create a smart grid-type platform with several localized electrical energy sources,as well as storage elements of different technologies.This MOZAHyC platform consists
49、 of setting up several energy sources,including hydrogen,that are coupled together by the conversion of renewable energies and storage stages.Figure 2:Production and Energy Storage network Project MOSAHyC135.Developing hydrogen internal combustion engines For many in the transportation sector,reduci
50、ng carbon emissions means adopting battery electric vehicles(BEVs)and fuel cell electric vehicles(FCEVs)13.But this doesnt mean the combustion of fuels will immediately be consigned to the engineering history books,we just need different fuels.One of these is hydrogen.Burning hydrogen in a piston-or
51、 turbine-driven thermal engine generates no CO2,just water and some NOx.The maturity of internal combustion engine(ICE)technology means systems can be adapted to hydrogen and other e-fuels synthetic fuels derived from an electrochemical process at a much lower cost than developing FCEVs.Some aspects
52、 associated with hydrogen combustion require further exploration before they can be applied extensively.The characterization of hydrogen combustion in comparison to“traditional fuels”like paraffin,natural gas,and methane is a crucial aspect.For example,flame speeds and flammability limits vary signi
53、ficantly with hydrogen concentration,reactant temperature,and pressure14.For numerical simulation,there are still gaps in the studies associated with hydrogen turbines.Furthermore,due to the high potential levels of NOX emissions,studies indicate variable levels which depend on the system configurat
54、ion,geometry,and operating conditions.Moreover,security aspects will have to be explored to prevent instabilities and flashbacks.This calls for significant digital engineering work.Hydrogen combustion as part of a hybrid solutionHydrogen combustion engineTechnologies based on hydrogen combustion(e.g
55、.,engines and turbines)are considered complementary to fuel cells(FC)in driving the hydrogen economy.Hydrogen combustion requires lower purity levels than most FC applications and could be carried out by blending with other fuels(i.e.,biomethane,natural gas,etc.),thus providing greater adaptability.
56、However,its use in mobile applications implies several technical,economic,social,and environmental challenges.In this context,the project HyPROPe concerns the digital prototype,test,and industrialization of an environmentally friendly“Flex-Gas”turbogenerator(using hydrogen,natural gas,biomethane,or
57、ammonia as fuels),shown in the digital prototype developed during this project in figure 3.The target power of this system is 250 HP(Approx.200 kW).As the main application,the microturbine is used in combination with an electric generator to power a heavy-duty hybrid truck.Other applications are env
58、isaged(i.e.,off-road,naval,and railways).Figure 3 Digital prototype for the HyPROPe project14Unlocking the Hydrogen AgeRetrofitting hydrogen propulsionA mathematical approach called the MHyTech(Modeling Hydrogen Aircraft Technologies)is used to evaluate the feasibility of a hybrid hydrogen-powered a
59、ircraft retrofit.This tool was developed to provide insights on the potential for combining hybrid-hydrogen technology use in commercial aircraft,including propulsive systems,such as hydrogen-fueled gas turbines,hydrogen fuel cell electric propulsion,lithium-ion batteries,but also current technology
60、 like kerosene-fueled gas turbines.Investigating the most sustainable architectural configuration is one proposed optimization approach.The complete mathematical model considers the design specifications of the propulsive system and,more specifically,the decision variables,namely the engines used,th
61、e amount of fuel,and the number of proton exchange membrane fuel cell(PEMFC)and batteries(if required).Another example is the view of a comprehensive pre-design and weight assessment methodology for electrical Vertical Take-Off and Landing vehicle(eVTOL)propulsion systems using hydrogen and batterie
62、s.Currently,over 100 eVTOL projects are under development,but the majority use batteries as power sources,reducing the mission range and autonomy.In aviation,the appropriate solution for decarbonization will depend on usage15.For example,electric batteries and fuel cells are a good solution for shor
63、t-and medium-haul aircraft with a limited number of seats.For short-haul commuter flights,replacing original turboprops with a fuel cell and electric powertrain is a potential solution,with the possibility of using hydrogen as a fuel.For long-haul aircraft,though,the only viable option is to combust
64、 fuel,which could be sustainable aviation fuels or hydrogen.The answer may be combining hybrid-hydrogen technology used in commercial aircraft,including propulsive systems,such as hydrogen-fueled gas turbines,hydrogen fuel cell electric propulsion,and lithium-ion batteries,but also current technolog
65、y like kerosene-fueled gas turbines.Hybrid hydrogen propulsionVIABLE is a Capgemini Engineering research project that offers new solutions for Urban Air Mobility.The project develops an eVTOL based on hydrogen and batteries.VIABLE conceives an eVTOL configuration with a maximum take-off weight of 3
66、tons,an autonomy of 90 minutes,and a maximal mechanical power of about 1 MW.For safety reasons,the size of each power supply,consisting of the hybridization of a fuel cell and a battery,is based on degraded scenarios(for instance,the loss of one power supply).This project proposes a methodology that
67、 includes several assets to verify the electrical hybridization concept of the power chain using fuel cells and batteries(FM2S),thermal validation of several proposed cooling solutions(SPEAC),and a weight assessment of the electrical architecture of the aircraft level(analytic weight assessment calc
68、ulator).When high-volume transmission via pipes is impossible,hydrogen is often transported as a liquid.156.Manufacturing low-cost and sustainable fuel cellsFuel cells(FC)are one of the most relevant hydrogen systems and are key in terrestrial,naval,and,more recently,aerial mobility.But fuel cell-ba
69、sed technology is an expensive and complex affair.FC systems conjure several technological constraints like high hydrogen purity requirements,lifespan,and the use of rare metals.Their energy performance is based on the stack composition,and the choice of materials composing the stack and the manufac
70、turing method used define the environmental impact of the fuel cell16.Understanding their life cycle and their manufacturing process is of huge importance to enabling low-cost and sustainable fuel cells.Ultimately,this requires a multi-criteria optimization of the global process and identifying the
71、optimal configuration possible by both reducing the environmental impacts of the process and minimizing operating costs17.Decision support will be necessary to identify the optimal solution(s)or to arbitrate compromises.The main challenge lies in the deployment of a methodology coupling the digital
72、model of industrial processes and the fuel cell lifecycle digital model.Modelling life cycle assessment of fuel-cell stack and manufacturing optionsWhile several works have been proposed to model the Proton Exchange Membrane Fuel Cell(PEMFC)system,its complexity,due to the multidisciplinary treatmen
73、t(electrochemistry,fluid mechanics,material science,etc.),limits the simulation to one part of the system,and not in totality.Apart from PEM,innovation is running on non-PEM technologies(such as alkaline,etc)and even in PEM,on the ceramic membranes instead of existing Nafion membrane.The work develo
74、ped here,named FC-Sim(Fuel-Cell Simulation),aims to rectify this by using a multidisciplinary approach,with the coupling of modeling,simulation,and the optimization of systems,and adding sustainability as the main parameter.This multi-physics simulation of the fuel cell systems focuses on the impact
75、 of the materials for each component(e.g.,the electrolyte membrane,the composition of the electrodes,the shape of the bipolar plates,etc.),and the performance of the fuel cell,considering PEMFC as the use case.The operating conditions are of particular importance,especially regarding the potential u
76、se in the aeronautical sector.Furthermore,only a few studies have included the environmental impacts generated by the manufacturing processes of fuel cells.In parallel with previous work,the FC-Manu(Fuel Cell Manufacturing)project is about the coupling of chemical process simulation and Life Cycle A
77、ssessment methodology to develop a model representation of the actual operation of the process(i.e.,a digital twin).Figure 4 Global methodology for the sustainable design of fuel cell manufacturing processes based on the coupling between process simulation and LCA.16Unlocking the Hydrogen AgeThe tra
78、nsformation journey of the hydrogen value chain:An end-to-end approachThe technology options covered in this paper illustrate the diversity and complexity of engineering choices facing stakeholders in the hydrogen value chain,who will find it challenging to resolve them all by themselves.They are po
79、int manifestations of the technology investment policies that are part of implementing an ambitious,all-encompassing transformation strategy and roadmap to convincingly create new workforce competencies,business processes,and technological capabilities,as well as coordinate a new industrial ecosyste
80、m.To assist them in the end-to-end transformation process,from creating the transformation strategyincluding business transformationto putting the technological roadmap into practice,stakeholders should identify trusted industrial partners that,with their combined competencies,can handle the whole s
81、pectrum of capabilities needed.Capgemini can help at all stages of the journey,from strategy to execution.With its mix of business transformation,systems integration,data science,and engineering services,Capgeminis Utilities Industry Platform utilizes digital transformation to prepare for a clean an
82、d safe hydrogen ecosystem.CONCLUSION 17ABOUT THE AUTHORSBragadesh DamodaranSenior Director Utilities India Industry PlatformDivyesh AroraHydrogen SMEUtilities India Industry PlatformJeremy CureHydrogen LeaderCapgemini Engineering,FranceFabien ClaudelProject Leader-SISTERCapgemini Engineering,FranceE
83、duardo Javier Carrera GuilarteProject Manager Capgemini Engineering,FranceEduard Solano SenzTechnical ConsultantCapgemini Engineering,FranceAlan Jean-MarieR&I Program Manager Capgemini Engineering,France Kvin CocqScientific Work Package Leader EE Capgemini Engineering,FranceJean Luc ChabaudieR&I Dir
84、ector Future of Energy Capgemini Engineering,FranceAntoine El HayekProject Leader-MOSAHyC Capgemini Engineering,France Abdelmalek MaloucheTeam Leader,EILiS Capgemini Engineering,France18Unlocking the Hydrogen AgeReferences 1.https:/www.iea.org/reports/the-future-of-hydrogen,p452.https:/www.iea.org/d
85、ata-and-statistics/charts/global-hydrogen-demand-by-production-technology-in-the-net-zero-scenario-2020-2030 3.https:/ of Contact Benot Calatayud,Director Transition nergtiqueRichard Biagioni,Vice President Energy Transition&Ecosystems19About Capgemini EngineeringWorld leader in engineering and R&D
86、services,Capgemini Engineering combines its broad industry knowledge and cutting-edge technologies in digital and software to support the convergence of the physical and digital worlds.Coupled with the capabilities of the rest of the Group,it helps clients to accelerate their journey towards Intelli
87、gent Industry.Capgemini Engineering has more than 55,000 engineer and scientist team members in over 30 countries across sectors including Aeronautics,Space,Defense,Naval,Automotive,Rail,Infrastructure&Transportation,Energy,Utilities&Chemicals,Life Sciences,Communications,Semiconductor&Electronics,I
88、ndustrial&Consumer,Software&Internet.Capgemini Engineering is an integral part of the Capgemini Group,a global leader in partnering with companies to transform and manage their business by harnessing the power of technology.The Group is guided every day by its purpose of unleashing human energy thro
89、ugh technology for an inclusive and sustainable future.It is a responsible and diverse organization of over 340,000 team members in more than 50 countries.With its strong 55-year heritage and deep industry expertise,Capgemini is trusted by its clients to address the entire breadth of their business
90、needs,from strategy and design to operations,fueled by the fast evolving and innovative world of cloud,data,AI,connectivity,software,digital engineering and platforms.The Group reported in 2021 global revenues of 18 billion.For more information please visit:Contact us at:Copyright 2023 Capgemini.All rights reserved.XV-VIII-MMXXII