Hydrogen: fuel with a future

"Water is the coal of the future" prophesied the science fiction author Jules Vernes as early as 1875, meaning "water that has been broken down by electricity".?This hydrogen will "secure the world's energy supply for the foreseeable future." Where do we stand today, almost 150 years later??A film and lecture evening on October 18, 2022, organized by the Unterguggenberger Institute in the W?rgl conference center, explored this question.

First of all: the course has been set for the hydrogen energy industry - especially in neighboring Germany, work is being done at full speed to switch to this climate-neutral energy source.?But also in Austria and here in Tyrol, where Tiwag is involved in several projects, including the implementation of the Power2X project in Kufstein.?Andreas Burger from Tiwag presented the innovative sector coupling system with a hydrogen center, which is scheduled to go into operation in 2024.?Hazardous goods specialist Manfred Holzer, commander of the Kundl company fire brigade and hazardous goods expert at the Tyrolean fire brigade association, cleared up safety concerns regarding the handling of the light, flammable gas hydrogen.

A "good to know" documentary by Bayrischer Rundfunk gave an insight into the current status of Germany's hydrogen initiatives for an energy transition for everyone.?Hydrogen is obtained by electrolysis - this requires water and electrical energy.?And here it is important to use "green electricity" instead of fossil fuels.?Hydrogen production lends itself as a storage medium for wind and solar energy.

Numerous companies such as Siemens Energy, the Mainzer Stadtwerke or the steelworks in Salzgitter are convinced that hydrogen will replace today's fossil fuels at no cost in the future.?Wind turbines are already standing next to blast furnaces, and Salzgitter AG wants to produce CO2-free steel by 2050.?The technology change is necessary.?Coke is still indispensable, the conversion of steel production to hydrogen is to begin in 2025, when the blast furnaces will be replaced by direct reduction plants.

The German steel industry is working intensively on converting to hydrogen.?Photo: BR Good to know

In Mainz, the public utility company is already adding 10% hydrogen to the natural gas that is used in gas boilers in households for heating.?The bus service in Mainz is also fueled with hydrogen, and the first tests with refuse collection trucks are being carried out in Bremen.?Hydrogen is lighter and more flammable than natural gas.?In Bitterfeld, materials that are best suited for a dense gas distribution network are being researched and tested; the solution has already been found with a composite.

Hydrogen trains are also already being tested in Germany.?In our neighboring country, only 61% of the route network is electrified.?In order to be climate-neutral by 2050, diesel-powered locomotives are being switched to hydrogen.?Hydrogen trains are quieter, run more smoothly and are vibration-free.?41 train sets have already been commissioned.?Hydrogen is also preferred here for cost reasons: One kilometer of electrification costs one to one and a half million euros.

Hydrogen technology in flight operations is still in its infancy.?Research is ongoing, but the energy source is only interesting for medium-haul routes at most.?Andreas Burger is convinced of Tiwag that it makes more sense to put routes under 1,000 km on the rails.?The CO2 emissions of all aviation account for 8% worldwide, so it makes more sense to convert other sectors first.

TIWAG COMMITMENT IN THE HYDROGEN SECTOR

As a Tyrolean energy supplier, Tiroler Wasserkraft AG is committed to developing a hydrogen energy economy, which falls within the area of responsibility of the subsidiary tinext, which was founded to support the energy transition.?The preparatory work for the construction of the Power2X Kufstein hydrogen plant has been going on for five years, and Andreas Burger is the project manager.

"Following a thorough examination, Kufstein has proven to be the best location in Tyrol to set up a sector coupling system with hydrogen electrolysis," explains Burger.?Hydrogen and oxygen are produced during electrolysis, for which a buyer was found in the Kirchbichl sewage treatment plant – the oxygen is used there to activate the clarification tanks.

"In Kufstein there is the Tigas valve station one, which transports natural gas for the whole of Tyrol.?Hydrogen can be fed into the natural gas network here by building an underground pipeline that crosses the Inn.?Also important is the possibility that, due to the proximity to the district heating plant, the waste heat can be used and fed into the Kufstein district heating network,” says Burger.?The waste heat is heated from 50 degrees C to 90 degrees Celsius using heat pumps.?"The efficiency of the system is thus over 90%," says Burger.

The operating site of the Power2X sector coupling system is in the Kufstein Forest, not far from the hydroelectric power station in Langkampfen, and would therefore also be ideally suited for a direct line to the power plant in order to guarantee "green electricity" as an energy supplier for hydrogen production.?"Since the legal framework for electrolysis means that no network tariffs have to be paid for 15 years, there is currently no economic need for this," says Burger.

The new hydrogen plant is scheduled to go into operation in 2024 and is considered a pilot plant with 5 megawatts in the final stage.?And is deliberately dimensioned in such a way that the system is not classified as a "Seveso operation".?"A maximum of two tons of hydrogen are produced here per day, which is enough to fill up 40 trucks," explains Burger.?Electrolysis, hydrogen storage and hydrogen filling stations for cars and trucks, which are spatially separated, are being built on the site.?In addition, 16 fast charging stations for electric cars and an electric truck charging station will be built.?"We're building a hub for CO2-free mobility not far from the autobahn," says Burger.

There are no safety concerns when handling the light, rapidly evaporating hydrogen.?Years of experience with hydrogen filling stations in operation show that the vehicles can be refueled without any problems despite the high gas pressure.?"In Bolzano, the buses have been running on hydrogen without any problems for seven or eight years," says Burger.

When planning the Power2X Kufstein sector coupling system, it was not yet clear in the discussion about the energy transition whether the classic electric motor or the hydrogen-powered fuel cell would prevail in CO2-free mobility.?"Both processes require batteries, including the fuel cell," says Burger.?Hydrogen has advantages in heavy goods traffic, especially over long distances.?Despite difficult framework conditions, since generally applicable standards for the new technology are still in their infancy, the project was accepted.?Burger: "We are convinced that this is the right way."

The Kufstein hydrogen plant and two other projects are currently the "flagships" in Tyrol, in which Tiwag is heavily involved.?The Tyrolean retail chain M-preis operates a hydrogen electrolysis plant in V?ls and is converting its truck fleet to the climate-neutral fuel.?The third in the group are the Zillertaler Verkehrsbetriebe ZVB.?"Here the start is difficult, there are still political discussions going on as to whether the electrification should be carried out with hydrogen or with electric overhead lines," says Burger.

Another tankhouse is also scheduled to go into operation in 2024 as a cooperation project in Jenbach at the Innio company.?"This means that three hydrogen projects will be implemented in Tyrol within a year and a half, and possibly even a fourth with the ZVB," explains Burger.

Experience is also to be gained with the feeding of hydrogen into the natural gas network, although Tigas is acting very cautiously here.?The hydrogen admixture is not 10% as in Germany, but only 4%.?"The natural gas network is suitable for this, as the example of Innsbrucker Stadtgas shows," says Burger.?The gas flows would not mix, can also be taken separately from the line.

Power2x Kufstein – The sector coupling plant for hydrogen electrolysis in Kufstein is scheduled to go into operation in 2024.?Photo: Tiwag/Burgers

Andreas Burger from Tiwag is project manager at Power2X Kufstein and gave an interesting overview of hydrogen initiatives in Germany and abroad.

HYDROGEN IN AUSTRIA AND THE EU

Austrian hydrogen research is coordinated from Tyrol, with the University of Innsbruck being involved.?Another hub is in Graz with several companies and institutions involved, and work is also being done on hydrogen technology at the Vienna University of Technology and in Upper Austria.?For example at VOEST in Linz, which has a 6 megawatt system in operation.?That's not nearly enough, but it's a start.

“In Europe, the focus is on Germany.?There they only talk about hydrogen, wanting to use it to replace Russian gas.?Especially in the wind regions in northern Germany, there is a lot of construction going on,” says Burger, giving an outlook beyond our national borders.?The train is heading towards hydrogen.?He is also receiving support from European directives and regulations.?Although southern Europe has ideal conditions for hydrogen production due to more solar radiation, only minor activities can be reported here at the moment.?Electrolysis requires direct current, which is supplied by photovoltaic systems.

Andreas Burger advocates using the Tyrolean resources for "green" hydrogen production.?He doesn't believe in importing hydrogen from the Middle East and thereby creating new economic dependencies.?"In Tyrol, 2 billion euros are spent every year on the purchase of fossil fuels.?Converting the 400,000 Tyrolean cars to electric drives would require 10% more electricity - that corresponds to a power plant complex like Sellrain-Silz," Burger is convinced.?Abroad, Tyrol is always envied for its optimal conditions with hydropower and hours of sunshine.?"Tyrol could easily be self-sufficient and even export hydrogen surpluses," says Burger.

RISKS WITH HYDROGEN??"NO WORSE THAN FOSSIL GAS"

Hydrogen is nothing new for the fire brigade and is no more dangerous than fossil gas - Manfred Holzer states this in the introduction: "Hydrogen evaporates upwards, petrol vapors downwards and are therefore much more dangerous."

Holzer recalled where hydrogen is already being used: bright annealing in metal processing, hydrogenation in oil or fat hardening, synthesis of ammonia, protective gas in semiconductor production and the glass industry, in welding technology, in electric machines as a coolant in turbo generators, as a fuel in vehicles and as an emergency power supply with fuel cells.

The dangers for the fire brigade are known in terms of gas leakage, fire, risk of explosion and container bursting as with petrol, natural gas and propane.?What is new is that hydrogen burns invisibly.?The minimum ignition energy is low, and the barely visible blue flame emits little radiant heat during combustion.?Due to the pressure conditions, hydrogen escapes very quickly and completely and is not a very reactive substance under normal ambient conditions.?"When the gas escapes, it whistles very loudly," says Holzer, describing the sequence of incidents in practice.?Safety precautions such as pressure relief valves and bursting discs are used in hydrogen technology.?“Every technology has its risks.?Even the production of petroleum is not harmless.?Ultimately, it is a political decision," says Holzer,?who describes himself as a "friend of a technology that makes us independent".?In any case, for the fire brigade, hydrogen is a “potential combustible like any other.”

Dangerous goods expert Manfred Holzer, commander of the Kundl company fire brigade and dangerous goods expert at the Tyrolean Fire Brigade Association, informed about the risk and how to deal with the dangerous goods hydrogen: "No more dangerous than fossil gases."

LOTS OF QUESTIONS FROM THE AUDIENCE

“Are there solutions with photovoltaics, hydrogen storage and fuel cells for single-family homes?” – the audience started with this question.?"Photovoltaics make sense, but does it have to be hydrogen as a storage medium??It is easier to heat water with a heating rod and use it as an energy store.?Hydrogen production is the most complex method and relatively expensive, you need electrolysis, storage, pressure vessels, etc.," admits Burger.?Not everything that works technically makes economic sense.?With PV systems, you should use as much electricity as possible yourself, and store surpluses in hot water or batteries.

ENERGY SAVING AND EFFICIENCY…

“If Tyrol wants to produce energy in a climate-neutral manner in 2050 – how can you bring the surplus energy from summer to winter??What role does photovoltaics play in this?” was another question.?"Currently around 200 megawatts of photovoltaics are installed in Tyrol - 200 megawatts of hydropower yields much more energy," explained Burger, who prefers hydropower in Tyrol: "Seasonal storage with hydropower is possible." the construction of new power plants, but saving energy and other user behavior are just as necessary in order to make better use of the electricity when the sun and wind are supplying it: "In Innsbruck there are still 30,000 boilers that run on off-peak electricity.?Here alone, a conversion to photovoltaic electricity accounts for 60 to 70 megawatts a day.”

Another area is Tyrol's tourism economy and the energy consumption of the ski areas.?“In the ski areas, 99% of the day electricity is required.?There are considerations to generate this with PV systems in high alpine areas, for example in the form of fences," says Burger.?"Tyrol has 10% of all snow cannons in the world, and 250 megawatts are installed here alone," he says, pointing out the potential.?There are also already approaches to operate the diesel-guzzling Radracs with hydrogen.

HYDROGEN IN THE TANK...

No entry for gas cars in underground car parks, such signs can be seen again and again - does that also apply to hydrogen cars??"The set of rules will change there," Manfred Holzer is convinced: "Hydrogen is very nice in underground car parks - if it escapes, it's quickly gone and doesn't collect on the ground.?A full hydrogen tank is blown off in a minute.” Risk awareness also needs to be worked on: “It is much more dangerous to make phone calls at gas stations now, and you shouldn’t put the car key in your trouser pocket either.” Electricity is one of the new risks for the fire brigade -Cars and pholovoltaic systems with battery storage in the basement, of course - but that also increases awareness of the dangers.?When pumps are used in flooded cellars, it is first measured whether they are voltage-free.

Andreas Burger answered the question about the range of hydrogen-powered vehicles: “You can drive 100 kilometers with one kilogram of hydrogen.?Cars have 7-8 kg of hydrogen on board, trucks currently 40 kg, with MAN working on increasing the capacity to 60-70 kg.”

"Why do hydrogen cars also need batteries?" was another question.?"These buffer batteries are smaller than electric car batteries and are required for smooth operation," says Burger.?However, this is not yet fully developed in heavy traffic: “In the high alpine region, the absorption of braking energy is an issue.?The battery must not be too small.?On the Brenner axis, mpreis trucks are now being used to test how the challenging transition can work.”

“Can hydrogen be produced from natural gas?” “Yes, you can do that with steam reforming.?This hydrogen is referred to as "grey hydrogen" - but from an ecological point of view it does nothing for the environment," explained Burger.?It makes sense to use renewable energy for hydrogen production.

Questions about the European electricity market were also discussed.?What happens in the event of a blackout??“Tyrol has coupling points at the state borders.?We can detach ourselves from the European grid, start up again with hydropower ourselves and supply essential regions in Tyrol ourselves," explained Burger.?This would not be possible with photovoltaic electricity, but it is possible with hydropower.?"Tyrol is an island, that's proven."

As far as the debate about the European electricity market is concerned, the Tiwag is “just a passenger”: “As soon as it is fed into the public grid, you are in international electricity trading.?The merit order system has been built up over the years and wasn't a problem until the high gas prices," says Burger.?The Tiwag could not get out there alone.

WIND ENERGY: UNSUITABLE IN TYROL

Tyrol is often confronted with the accusation that there are no wind turbines here.?With good reason, as Andreas Burger explained: “The problem is the location.?There is often turbulence on the ridges and, above 2,500 meters, rotors icing up, which would have to be heated.?There are no constant wind conditions on the mountain, at high wind speeds there is a risk of overloading and shutdown.?That's physics," explains Burger, explaining why wind energy doesn't play a role in Tyrol.?And what about valley winds??A suitable location was identified in Jenbach - but that would be a huge system, 150 meters high with a blade diameter of 100 meters and an output of 2 or 3 megawatts.?"Does it make sense??Tyrol should better focus on hydropower and photovoltaics.?We have water and sun.

Energy production in Tyrol cannot grow indefinitely, even in the renewable sector.?It is inevitable that we all reconsider our energy behavior and adapt to new requirements.