In the race to achieve net-zero greenhouse gas emissions by 2050, industries are making significant strides toward sustainable energy solutions. Among these efforts is the TWINGHY project, which is pioneering the conversion of a conventional steel reheating furnace to operate on hydrogen. This transition holds promise for reducing the carbon footprint of the metallurgical industry, traditionally dependent on fossil fuels. However, it also brings to the forefront the critical importance of safety, particularly when working with hydrogen—a gas with unique properties and challenges.
Working on the TWINGHY project is being a remarkable journey, giving me a deep appreciation for the complexities involved in ensuring safety when dealing with hydrogen. Hydrogen, while a clean energy carrier, presents several safety concerns due to its physicochemical properties. It is extremely flammable, diffuses rapidly, and has a propensity to cause material embrittlement. From the outset, we knew that addressing these concerns was paramount. Our approach was to conduct a comprehensive Hazard and Operability Study (HAZOP), meticulously examining potential hazards and operability issues associated with the shift to a hydrogen-based system. This involves identifying deviations from design intent, assessing risks, and recommending measures to mitigate identified hazards.
The HAZOP study for TWINGHY identified 47 critical points, with 4 categorized as critical risks and 15 as high risks. These findings underscored the inherent dangers of hydrogen, such as the risk of fire and explosion. To mitigate these risks, the study provided 19 specific recommendations, including enhancing personnel training, implementing physical protection measures, ensuring pressure control, managing ATEX zones, and establishing emergency response protocols. Implementing these recommendations will reduce the identified risks to acceptable levels, though some moderate risks will remain, primarily dependent on human intervention and procedural adherence. Continuous monitoring and improvement processes are crucial to adapting to evolving conditions and technologies.
Collaborating on TWINGHY is being an eye-opener. The meticulousness required for the HAZOP study and the subsequent implementation of safety measures underscores the critical role of safety in hydrogen-based innovations. By identifying and addressing potential hazards, TWINGHY not only aims to ensure the successful conversion of the steel reheating furnace but also sets a benchmark for best practices in hydrogen safety within the metals industry. My experience with TWINGHY reinforces the importance of a safety-first approach in pioneering projects. It’s a journey that demands diligence, expertise, and an unwavering commitment to protecting both people and the environment.
Author: Anna Domènech, Head of Innovation at Celsa