An Oversized Pipeline: a Potential Solution for Seamlessly Integrating Intermittent Green Hydrogen Production and Low Carbon Fuel Synthesis

Abstract This paper explores the challenges and solutions associated with integrating intermittent electrolytic hydrogen production from variable electricity sources, such as wind and solar farms, into chemical processes requiring steady hydrogen feedstock (e.g., ammonia synthesis process). Focusing on a hypothetical scenario closely resembling actual project requirements in the industry, the study evaluates three design options for hydrogen storage and transportation. Design Option 1 utilizes oversized pipelines, leveraging pipeline packing/unpacking mechanism, while Design Option 2 involves on-site storage of hydrogen in pressurized storage tubes co-located with the electrolyzer plant. Design Option 3 incorporates a Battery Energy Storage System (BESS). This study shows that the use of both Design Option 1 and 2 can be both technically and economically feasible. In Design Option 1, the cyclical nature of pipeline pressure and its impacts on pipeline integrity in hydrogen environment must be assessed, which vary based on project-specific requirements such as hydrogen production trend, supply rate, and pipeline size. In Design Option 2 the process risks concerns related to the number of storage tubes and connections required must be evaluated, including the potential radius of impact in the event of failures leading to uncontrolled releases of hydrogen gas. Design Option 3, on the other hand, would incur a substantially higher project cost compared to the other two aforementioned options and hence was not evaluated further.