Category: Industry Trends

High Power Rectifiers for Hydrogen Production

The best solution for efficient and reliable DC power supply

for large scale industrial water electrolysis

Scaling up H₂ capacity to power the future by

leveraging ABB’s comprehensive experience

Hydrogen is a key fuel for tomorrow’s economy

Hydrogen electrolysis can serve as a sustainable bridge in

the gap between electricity and chemical energy carriers,

thus allowing fossil free powering where direct electrifica

tion is not feasible. This means hydrogen can play a crucial

role in achieving government and corporate sustainability

targets, with ABB supporting these aims by providing

best-in-class electrification technology for the hydrogen

economy of tomorrow.

Annual demand up to hundreds of millions of tons of H₂

Ammonia:  Direct use for fertilizer production

Synfuels:  Replacement in combustion engines

Industry:  Chemical, steel, cement and others

Buildings: Private and commercial heating

Transport:  Fuel for cars, rail aviation & ships

Power:  Energy storage for reconversion

Refining: High quality fuels and feedstock

Services

Keep your plant running smoothly with ABB Care

The situation

As new hydrogen facilities are being planned, we can help from a consultation

perspective to ensure that the various disciplines are optimized, and we can

help with installation and commissioning as well as long-term service.

Our offering

ABB provides flexible annual service agreements (ABB Care) tailored to your

specific needs. These agreements may include a simple support rate or be built

up to cover your plant’s complete electrical services needs to keep it running

smoothly. As indicated by the service wheel on the right, ABB offers a whole

portfolio of automation, electrical and software services, to cover your plant’s

complete services.

Benefits

• Increased uptime and safety

• Reduce risk of failures

• Increased ROI through continuous improvement

Available services

• Cyber security software and services

• Asset management

• Annual and on-demand training

• 24/7/365 technical support

• Life cycle parts management

• System evolutions and upgrades

• HMI upgrades and replacements

• PLC integration/consolidation into DCS

• Asset Health Management

• Remote and on-site service

Benefits

• Increased uptime and safety

• Reduce risk of failures

• Increased ROI through continuous improvement

Benefits

• Enhanced efficiency:

s Utilizes real-time efficiency curves for each Electrolyzer module

s Ensures optimal plant performance across varying setpoints

s Improves efficiency across various Electrolyzer models

• Reduced electrical life cycle costs:

s Up to 20 % savings through optimized electrical source usage

s Considers downstream process obligations for comprehensive optimization

• Improved decision-making:

s Increased transparency with advanced monitoring and reporting

s Facilitates quick identification of improvement areas

s Enables data contextualization for efficient plant operation

s Streamlines regulatory reporting processes

Our offering

• Predictive optimization of electrolyzers based on hydrogen demand,

renewable energy production, and market schedules

• Real-time control of electrolyzer modules to maximize efficiency and

ensure safety

• Participation in various ancillary service markets, including frequency and

secondary reserves

• Comprehensive monitoring of electrical energy, heat, and mass flows

throughout the process

OPTIMAX® Energy Optimizer

Optimizing energy costs for

green hydrogen production

The green hydrogen industry faces challenges in harnessing renewable energy

efficiently and economically. As the energy sector shifts from a single to multiple

energy source model, optimizing production and consumption of energy is crucial.

OPTIMAX plays a vital role in this transformation.

ABB Ability™ Energy Management – OPTIMAX® maximizes energy value by

strategically managing energy flows and assets. This solution helps implement the

optimal operation of green hydrogen production plants to achieve state-of-the-art

efficiency and safety through modular design.

Our offering

• Predictive optimization of electrolyzers based on hydrogen demand,

renewable energy production, and market schedules

• Real-time control of electrolyzer modules to maximize efficiency and

ensure safety

• Participation in various ancillary service markets, including frequency and

secondary reserves

• Comprehensive monitoring of electrical energy, heat, and mass flows

throughout the process

Control Room Solutions

Improving operator effectiveness

The control room is the heart and core of all technology in an industrial

environment. A poorly planned and designed control room can lead to costly

mistakes that can be related directly to human error. A control room design must

consider the human, the workflow as well as the technology. Proper design will

ensure optimal operational efficiency not just today, but for the future. Professional

design and planning create a solution where nothing is overlooked.

Our offering

Proper planning in advance can save costs, as well as create an optimal control room

environment for operator effectiveness. A well-designed control room solution,

whether it is a new-build or upgrade, total or partial, is your assurance of safer,

more alert operators, more attentive monitoring, quicker and more efficient

reaction times, and higher productivity.

Every detail counts when investing in your control room. Involving ABB in an early

phase of your project ensures that the operator working environment is planned

and furnished as a complete solution, avoiding many of the difficulties and costs

often associated with a new control room. Thanks to experiences from multiple

industries and countries, ABB control room solutions both drive efficiency and

cut total costs.

Benefits

• Control Room design team with over 20 years’ experience

• A step-by-step approach for greenfield projects

• Scalable process from advanced and comprehensive studies to simple

and quick support

• A wide selection of products to back up the final design

Benefits

• Operational efficiency: System 800xA DCS platform unifies electrical and process

control, optimizing architecture essential for green hydrogen production

• Cost reduction: Integration of third-party systems and reduced complexities lower

CAPEX and OPEX, enhancing economic viability

• Safety and data utilization: Integrated power and process management enhances

safety and improves decision-making through unified data access

• Predictive maintenance: Advanced asset management reduces downtime and

costs, ensuring smooth hydrogen production

• Agile market response: Standardized, flexible architecture allows quick

adjustments to market trends in the evolving green hydrogen industry

• Sustainability goals: Optimized energy efficiency and reduced life cycle costs align

with critical green hydrogen initiatives and emission reduction goals

ABB Ability™ System 800xA®

Integrated Process & Power Automation

Revolutionize your Green H2

production with

ABB’s unified automation solution

Our offering

• A comprehensive, integrated automation solution that unifies power

management, process control, and safety systems into 800xA DCS platform

essential for Green Hydrogen Projects

• Seamless integration from third party systems into 800xA DCS platform enabling

better collaboration and decision-making

• Industry-leading control architecture through a unified system platform that

provides functionality from field-level to executive level

• Optimized project execution through standardized control modules and libraries,

resulting in faster delivery and lower project risks

• A focus on cybersecurity, ensuring protection of assets and equipment as well as

mitigating cyber threats across the entire plant network

• Advanced asset management strategies such as predictive maintenance, and

electrical condition monitoring, to and improve overall equipment and operator

effectiveness

• Operator Training Simulators (OTS) initiated at the front-end engineering design

(FEED) stage to reduce risks and enhance engineered design throughout the

project path, all the way to and including operations

Digital

Energy and operational efficiency

Employing the most efficient automation solutions and leveraging real-time data

insights can reduce your hydrogen production costs and provide safety & security.

Our offering

ABB offers a variety of comprehensive digital tool sets to optimize your operations.

• ABB’s Energy Management (OPTIMAX®) allows for Green Hydrogen facilities to

monitor, control and optimize multiple power feeds and uses predictive

optimization to exploit forecasts for weather and grid prices, while allowing you

to monitor and reduce your CO2 emissions

• ABB Asset Performance Management (APM) to reduce unscheduled maintenance

costs by helping you better understand and predict your asset performance

• ABB Ability™ Cyber Security portfolio offerings mitigate cyber risks by

identifying threats, automating compliance, and deflecting cyber-attacks

• ABB Connected Worker/Operator Effectiveness enables the interactive execution

of procedures at both plant and enterprise levels. Guide operators and key

stakeholders with actionable insights. It integrates with the plant control

system, offering improved safety and increased efficiency for startup, routine

and shutdown activities as well as for day-to-day rounds, all from the comfort

of your devices

Benefits

• Reduce OPEX by up to 20 %

• Balance available energy sources to ensure availability and efficiency

• Simulate and virtualize optimal energy flows and use adaptive control to

achieve them

• Forecast energy demand and supply

• Ensure the security and availability of the facility’s infrastructure

• Optimize asset performance

ABB offers a variety of comprehensive digital tool sets to optimize your operations.

• ABB’s Energy Management (OPTIMAX®) allows for Green Hydrogen facilities to

monitor, control and optimize multiple power feeds and uses predictive

optimization to exploit forecasts for weather and grid prices, while allowing you

to monitor and reduce your CO2 emissions

• ABB Asset Performance Management (APM) to reduce unscheduled maintenance

costs by helping you better understand and predict your asset performance

• ABB Ability™ Cyber Security portfolio offerings mitigate cyber risks by

identifying threats, automating compliance, and deflecting cyber-attacks

• ABB Connected Worker/Operator Effectiveness enables the interactive execution

of procedures at both plant and enterprise levels. Guide operators and key

stakeholders with actionable insights. It integrates with the plant control

system, offering improved safety and increased efficiency for startup, routine

and shutdown activities as well as for day-to-day rounds, all from the comfort

of your devices