HySynergy green H2 production plant

Rapidly accelerating renewable energy sources such as wind and solar is essential in society’s transition to net zero. But a key challenge remains that these energy sources are intermittent, meaning they only generate power when the sun shines or the wind blows. Power-to-X helps solve this fundamental challenge by converting renewable energy into green hydrogen – reducing the risk that renewable energy is wasted while also decarbonising hard-to-abate sectors.

With their new HySynergy plant in Fredericia, Denmark, hydrogen fuel company Everfuel is rapidly scaling production and building one of the largest facilities of its kind in Europe.

Although the initial capacity will be just 20 MW, expansions will bring that figure to 1 GW in three phases:

HySynergy will produce hydrogen for Everfuel’s own hydrogen refuelling stations. From there, it will supply offtakers in mobility and industry, while also supplying hydrogen to the neighbouring Crossbridge Energy refinery and surplus heat to the local district heating system.

The first phase will have a production capacity of about eight tonnes of green hydrogen per day and ten tonnes of storage capacity.

The project will significantly contribute to Denmark’s transition to net-zero and decarbonisation of the transport sector by providing access to green fuels for heavy-duty and private vehicles and replacing fossil fuel-based hydrogen and natural gas in industry processes.

It will also support the reduction of the carbon footprint within Crossbridge Energy’s refinery next to the HySynergy plant.

The initial CO2 emission reduction potential from supplying hydrogen from HySynergy to the mobility and industry sectors is 214,000 tonnes of CO2 annually.

Ramboll developed and matured the concept and detailed design of the plant’s Emergency Shut Down (ESD) and relief system, as well as the hydrogen interface piping. The detailed design included piping and instrumentation diagrams, data sheets, 3D modelling, piping specifications, and making electrical and instrumentation work packages ready for purchase and construction.

Ramboll also performed a series of risk and safety studies during project development to ensure high safety standards at the plant and its surroundings. Furthermore, Ramboll offered support and advice in obtaining the required safety permits and established the summarising safety document, which was fundamental in securing the permit to begin construction.

Watch a film about the HySynergy project: https://www.everfuel.com/app/uploads/2022/02/HySynergy80Mb.mp4