Triple carbon reduction… but many more lessons learned

This is a guest blog by Giulia Pizzagalli from Anglian Water for the Triple Carbon Reduction project, which was awarded funding in Water Breakthrough Challenge 1.

The Triple Carbon Reduction (TCR) project, led by Anglian Water with a consortium of 11 partners, and part of the Breakthrough 1 round, aims to explore the co-location of hydrogen production in wastewater treatment facilities, using the by-product of electrolysis (oxygen) to enhance performance of a novel biological wastewater treatment process, Membrane Aerated Biofilm Reactor. This synergy aims to achieve three main carbon benefits:

1. The reduction of electricity consumption
2. The reduction of nitrous oxide process emissions from secondary wastewater treatment
3. The generation of a new form of renewable energy through hydrogen.

What is the project trying to achieve?

The water sector is in a unique position to exploit this process as it has both the resources (such as water and renewable energy) and end uses for the hydrogen and oxygen products, creating an elegant circular system to reduce carbon and recover resources.

To demonstrate the concept of the Triple Carbon Reduction, integrating MABR and electrolysis, a pilot plant will be run for six months at Anglian Water’s Cambridge Water Recycling Centre.

While at scale up the aim will be to use treated effluent from wastewater, potable water will be supplied to the plant at demonstration scale and pass through an electrolyser which uses a renewable power supply. Here, Green Hydrogen is produced, which can be either used in on site power generation, or be sold. Oxygen is also generated as a by-product of electrolysis, and used as a resource in the Membrane Aerated Biofilm Reactor (MABR) treatment process, whereby nitrous oxide emissions and energy consumption will be reduced.

It is a truth universally acknowledged that an innovation project worthy of the name will be unpredictable even at the best of times; add producing and storing hydrogen in a wastewater treatment facility, a first for us at Anglian Water, and the project suddenly becomes in equal measure exciting and challenging.

The opportunities for learning, however, are plenty. Here are some key insights gathered along the way, around supplier engagement strategies, Health and Safety (H&S) best practice and onboarding of technical specialists.

Triple carbon reduction: three areas of insight

1. Supply chain engagement and procurement process

When procuring an electrolyser, size does, in fact, matter. Most suppliers in the hydrogen space tend follow current market demand and therefore cater to bigger capacity (at least over 1MW), driving up the economy of scale. We only ever planned to operate a smaller demonstration plant, due to the limited oxygen demand for the size of MABR, and engagement proved to be challenging: many suppliers, while interested in the innovative nature of the project, could not commit to a partnership or enter a tender due to their business developing in a different direction.

Once a supplier is secured, it is advisable to build some lag into the programme. The hydrogen industry is booming with demand, components lead times are often up to years, and technical experts are a hot commodity, potentially leading to delays and high turnover in the project team.

2. Health and Safety requirements

Unlike more common flammable gases such as biogas, hydrogen has distinct characteristics that require special handling and safety measures, above and beyond common water sector practices and procedures. Hydrogen is the lightest element, and it diffuses rapidly, which can lead to leaks if not properly managed. Additionally, hydrogen has a wide flammability range and low ignition energy, making it more prone to combustion.

Understanding these properties is crucial for a safe and effective design and construction process, which will need to undergo comprehensive safety reviews to avoid or mitigate risk for personnel and site assets. Whilst most of these are standard practice in our sector, such as  HAZOP (Hazard and Operability Study) and DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) assessment, some additional reviews and studies, such as blast modelling, or bow-tie analysis, will need to be carried out.

They say lightning never strikes twice, but when installing a hydrogen producing facility for the first time, even unlikely events need to be planned for, to build a safe and effective response system in case of emergency. For this reason, engaging with hydrogen H&S professionals early in the project can ensure that all safety measures (i.e. lightning protection, setback distances) are planned and implemented effectively, helping to manage risks and ensuring compliance with safety standards during design, construction and operation.

3. Lagging Technical Resources

However, the rapid pace of development in the hydrogen sector often outstrips the availability of technical resources.

Due to the lack of specialist skills and hydrogen expertise in-house, a number of safety reviews for TCR had to be commissioned to independent third parties to assure that all standards had been met, increasing delays for procurement and resourcing, and adding costs to the project.

Investing in training and development programs for technical staff can help bridge this gap. Additionally, collaborating with academic institutions and industry experts can provide access to the latest knowledge and technologies.

In conclusion: seize the opportunities and expect the unexpected (including hypothetical rodents)

In conclusion, hydrogen projects hold immense potential for the water sector and could significantly help reach our Net Zero goals.

By prioritizing safety, building a skilled workforce, fostering collaboration, and planning ahead, new hydrogen initiatives can successfully navigate the challenges and seize budding opportunities. However, it is crucial to acknowledge that no innovation project is entirely predictable; timescales (and consequently, costs) will slip more often than not, and there will always be at least one surprise in store.

Strictly hypothetically, some chilly rats could take refuge in the site office and force the team to dip into the contingency fund to relocate for a few weeks. We take it in stride, it makes for some good stories along the road!

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Find out more about the Triple Carbon Reduction project on the Anglian website.