The world is racing to reduce its dependence on fossil fuels, even as global electricity demand is forecast to rise in 2024 and 2025 at an expected growth rate of around 4%. That is the highest annual growth rate in the past two decades, excluding spikes following the global financial crisis and the Covid-19 pandemic.

In the face of this transformation, new energy carriers such as hydrogen, ammonia and methanol are becoming essential components of a sustainable energy landscape. However, these solutions bring their own set of challenges, particularly in terms of safety and risk management. A multi-faceted approach is needed to address these challenges.

Mapping Security in the New Energy Era

Handling hazardous gases requires the ability to respond quickly. Gas supply disruptions, along with the risk of fires and explosions, pose a significant risk – almost a third of all incidents result in fires and around half result in explosions. Without a solid emergency plan, the consequences for personnel can be serious. In addition, failure to comply with official operational documentation can result in significant penalties for the facility.

“Operators and designers have a duty to protect life,” explains Oliver Bornholdt, Global Business Development Manager at Dräger. “If an incident occurs, you must prove that you did everything you could to avoid it.”

While there is no 100% protection against unforeseen events, a comprehensive security and crisis management system can reduce the risk of such an event occurring.

Implementing an effective safety strategy includes a thorough risk analysis of the gases being handled, appropriate technical equipment and well-trained employees. In addition, a well-structured evacuation and rescue concept is crucial, as it coordinates emergency resources and personnel, providing managers with certainty in their decision-making. Dräger specializes in helping plants and facilities prepare for the worst-case scenarios, equipping them to respond in the best possible way.

Technology that will ensure hydrogen safety

To enhance the effectiveness of these safety protocols and prevent potential threats, Bornholdt emphasizes the importance of three key technologies. These include ultrasonic leak detection, point gas detection, and flame detection. Each technology is specifically designed to identify risks, such as leaks and fires, at an early stage, preventing worst-case scenarios before they happen. This proactive approach is key to maintaining safety.

Ultrasonic detectors are often seen as a quick and easy leak detection option in many facilities. They use advanced microphone technology to capture high-frequency ultrasonic sounds that are produced when a high-pressure gas leak occurs. This technology is particularly good at quickly detecting hydrogen leaks in large, outdoor industrial environments.

On the other hand, point gas detectors use either catalytic or electrochemical sensors to detect hydrogen. Catalytic sensors are designed to react with gases, such as those found in industrial environments, by changing their electrical resistance, which can be measured to detect the presence of explosive gases. This feature makes them particularly useful in preventing explosions. On the other hand, electrochemical sensors are excellent in environments where detecting even trace amounts of gases, such as hydrogen, is critical. These sensors operate by producing a chemical reaction that generates an electric current, allowing for fast and sensitive detection in confined spaces.

Another key safety tool is flame detection. The new triple IR sensors are particularly effective because they can identify the unique characteristics of a hydrogen flame, which requires different detection technology than hydrocarbon fires.

The detection technology a facility will need is very unique. There is no one-size-fits-all solution. It’s a strategic endeavor. “Our approach to technology security is holistic,” Bornholdt says. “No single technology can provide complete protection. Instead, a carefully planned set of technologies is essential to effectively protecting facilities.”

Theory in practice: Change is already happening

Salzgitter Flachstahl knows how important this is first-hand. The steelmaker is actively reducing its carbon dioxide (CO2) emissions by switching from traditional coke-fired blast furnaces to a more sustainable hydrogen-based direct reduction plant. In this transformation, the company is integrating advanced technologies, including those from Dräger, to ensure the efficiency and safety of the new processes.

Dräger solutions, including the Dräger PEX 3000 and Polytron 7000 systems, are integral to ensuring safe operations as Salzgitter Flachstahl transitions to hydrogen. These systems detect flammable gases and provide precise hydrogen measurements, preventing potential safety incidents. In addition, Dräger supports Salzgitter Flachstahl with specialized training programs, increasing employee safety awareness in handling hydrogen. Building advanced safety solutions can significantly help Salzgitter Flachstahl achieve its ambitious goal of transitioning to low-carbon steel production by 2033.

As industries continue to decarbonize their operations towards more sustainable energy sources such as hydrogen, the importance of implementing rigorous safety measures cannot be overstated. Dräger’s extensive experience and advanced technology solutions ensure that this transformation does not compromise human safety or operational integrity. By implementing advanced gas detection and emergency management systems, key industry players are better equipped to safely navigate the complex challenges posed by the transition to new energy sources, providing a solid safety net during this significant change.