HYBRIT: Large-scale storage of fossil-free hydrogen gas

The HYBRIT initiative was launched in 2016 by Sweden’s SSAB, LKAB and Vattenfall, with the aim of developing the world’s first fossil-free, ore-based iron- and steelmaking using fossil-free electricity and hydrogen gas. The initial pilot project focused on the production of fossil-free sponge iron for steel production. The second pilot project has now completed, demonstrating the technical feasibility of storing fossil-free hydrogen gas for the industrial-scale production of fossil-free iron and steel.  

Hydrogen is expected to play in key role in electrifying hard-to-abate industrial processes such as cement production and steelmaking. By storing surplus hydrogen when electricity prices are low and using it when prices are high, a large-scale hydrogen user could make significant cost savings, according to the HYBRIT partners. Optimised operation of the storage facility was undertaken in real time during the pilot project, both against the spot price and intraday market. Savings of 26–31% of variable operating costs were demonstrated in practice, report the partners. They add that simulations of future scenarios for the Swedish electricity market indicate savings of about 25–40% of variable operating costs could be possible when the first commercial plants are commissioned.

The pilot project involved the design and construction of a 100 m³ underground hydrogen storage facility in Svartöberget, near the sponge iron production site in Luleå, Sweden. Utilising steel-lined rock cavern technology, the storage facility has undergone rigorous mechanical testing equivalent to approximately 50 years of operation. No leaks were discovered from the steel-lined rock cavern over multiple storage campaigns ranging from three to six weeks.  

The pilot project for the storage of fossil-free hydrogen gas is to be extended until 2026, to carry out additional tests to further improve the design of commercial hydrogen storage.

The results of the project confirmed the safety, functionality and performance of the facility, marking a major step towards scaling up the technology, according to Mikael Nordlander, Director of Industry Decarbonisation at Vattenfall’s Industrial Partnerships.  

Meanwhile, Martin Pei, CTO at SSAB, notes that the HYBRIT technology not only supports the production of fossil-free iron and steel but also contributes to reducing global CO₂ emissions. The project partners estimate it has the potential to decrease Sweden’s and Finland’s emissions by 10% and 7% respectively.

The HYBRIT project in Sweden aims to develop the world’s first fossil-free, ore-based iron- and steelmaking using fossil-free electricity and hydrogen gas

Photo: Vattenfall

DNV launches H2MET joint industry project

Meanwhile, DNV has launched the H2MET joint industry project (JIP) to advance metrology for 100% hydrogen flow applications. Based at DNV’s Technology Centre in Groningen, Netherlands, the initiative will build on previous work in renewable gases and CO₂. It will provide a platform for industry collaboration, enabling hydrogen operators and technology providers to share knowledge and establish operational limits for hydrogen flow metering. Central to the project is a highly accurate, traceable reference system that will assess the performance of various hydrogen metering technologies, supporting the European hydrogen flow traceability chain and future hydrogen trading.

‘The H2MET project is a crucial step in driving technological advancements for hydrogen trading,’ comments Øyvind Nesse, Senior Vice President at Equinor. ‘By ensuring that hydrogen flow measurement technologies meet the required standards of accuracy and reliability, we are contributing to a safer and more efficient energy transition.’

Prajeev Rasiah, Executive Vice President and Regional Director for Northern Europe, Energy Systems at DNV, adds: ‘As hydrogen markets mature, robust metrology will be essential to ensure transparency, accuracy and trust. By bringing together industry leaders in the H2MET JIP, we are not only addressing technical challenges but also laying the foundation for a globally recognised hydrogen measurement framework – critical for scaling hydrogen as a cornerstone of the energy transition.’

Hydrogen sensor innovations

In other news, scientists at the UK’s University of Manchester, in collaboration with King Abdullah University of Science and Technology (KAUST) in Saudi Arabia, have developed a hydrogen sensor that is claimed could ‘offer a breakthrough in hydrogen safety technology’. The sensor can detect even the tiniest amounts of hydrogen in seconds, reportedly outperforming current portable commercial detectors. Its small size, affordability and energy efficiency make it a versatile tool for various applications, including homes, industries and transportation networks, say the researchers.

The new organic semiconductor sensor relies on a process known as ‘p-doping’, where oxygen molecules increase the concentration of positive electrical charges in the active material. When hydrogen is present, it reacts with the oxygen, reversing this effect and causing a rapid drop in electrical current, allowing for fast and reliable detection.

The sensor has been tested in real-world scenarios, such as detecting leaks from pipes, monitoring hydrogen diffusion in closed rooms, and mounted on drones for airborne leak detection. It can be made ultra-thin and flexible and could be integrated into smart devices, enabling continuous distributed monitoring of hydrogen systems in real time, suggest the scientists.

Finally, the Fraunhofer Institute for Physical Measurement Techniques IPM in Freiburg, Germany, has developed three sensor systems to detect hydrogen leaks in pipelines and tanks. These sensors provide continuous monitoring, crucial for the safe deployment of hydrogen infrastructure.

The first technology is an ultrasonic sensor utilising the photoacoustic effect. The sensor can detect hydrogen leaks by registering changes in the resonance frequency when hydrogen enters the container. It is precise enough to detect minimal levels of contamination, ensuring the purity of hydrogen used in fuel cells, says the research institute.

It has also developed a laser spectrometer designed for remote detection of ammonia, which is highly toxic and is used as a carrier matrix for hydrogen. The device can check pipelines or tanks from a safe distance of as much as 50 metres. It can also be mounted on robots or drones for industrial inspections.

The third sensor is based on the principle of Raman spectroscopy. The Raman effect is produced by interactions between light and matter. The light reflected off the matter has a different wavelength than the light emitted at the source. This means that every kind of matter has its own spectroscopic ‘fingerprint’. Fraunhofer’s filter-based Raman sensor selectively detects hydrogen in complex media. The portable system can be used as a mobile testing station, providing a cost-effective solution for hydrogen production monitoring.