Periodic Reporting for period 1 - OPTHYCS (OPTIC FIBRE-BASED HYDROGEN LEAK CONTROL SYSTEMS)
Okres sprawozdawczy: 2023-01-01 do 2024-06-30
The OPTHYCS project aims to develop a new system for continuous leak detection based on optic fiber sensor technologies, ensuring safety and sustainability of the future hydrogen-based energy system.
Acknowledging the critical need for effective leak detection methods in light of the environmental impact of hydrogen emissions, OPTHYCS introduces an innovative approach by developing a solution that involves cutting-edge coating materials for Fiber Bragg Gratings (FBGs) and the creation of a combined detection system merging FBGs with distributed acoustic and temperature-based detection technologies. The aim is to develop a system that combines the benefits of these different detection technologies and to validate it at realistic use cases scenarios, aiming to achieve at least TRL 5, being the basis for further R&D and potential market entrance in the longer term. The developments include the optimisation of the coating materials using plasma techniques for its deposition, ensuring properties like coating adhesion and increased hydrogen sensitivity, the development of new interrogators specifically designed for this system and a software that will manage for the user the signals from the fiber optic and interrogators.
The project aims to develop a high-resolution sensor with a sensitivity of 10 ppm and an accuracy of ±10%. It will detect hydrogen concentrations up to the Lower Explosive Limit (LEL) of 4%, with detection and recovery times of less than 1 minute. The sensor will operate reliably in temperatures ranging from -20°C to 70°C, be maintenance-free, and have a lifespan of over 5 years. Additionally, it will exhibit no interference from other gases, ensuring precise and reliable hydrogen detection in various environmental conditions.
The outcomes of this project are poised to significantly impact the field, offering safer and more reliable solutions for the hydrogen-based energy landscape.
Acknowledging the critical need for effective leak detection methods in light of the environmental impact of hydrogen emissions, OPTHYCS introduces an innovative approach by developing a solution that involves cutting-edge coating materials for Fiber Bragg Gratings (FBGs) and the creation of a combined detection system merging FBGs with distributed acoustic and temperature-based detection technologies. The aim is to develop a system that combines the benefits of these different detection technologies and to validate it at realistic use cases scenarios, aiming to achieve at least TRL 5, being the basis for further R&D and potential market entrance in the longer term. The developments include the optimisation of the coating materials using plasma techniques for its deposition, ensuring properties like coating adhesion and increased hydrogen sensitivity, the development of new interrogators specifically designed for this system and a software that will manage for the user the signals from the fiber optic and interrogators.
The project aims to develop a high-resolution sensor with a sensitivity of 10 ppm and an accuracy of ±10%. It will detect hydrogen concentrations up to the Lower Explosive Limit (LEL) of 4%, with detection and recovery times of less than 1 minute. The sensor will operate reliably in temperatures ranging from -20°C to 70°C, be maintenance-free, and have a lifespan of over 5 years. Additionally, it will exhibit no interference from other gases, ensuring precise and reliable hydrogen detection in various environmental conditions.
The outcomes of this project are poised to significantly impact the field, offering safer and more reliable solutions for the hydrogen-based energy landscape.
The consortium has determined the design specifications and requirements of the system from technical, environmental and economical perspectives. Different needs for different future use cases were identified, as the aim is to create a robust and reliable system for hydrogen detection in diverse industrial environments.
Progress has also taken place in the development of sensor solutions. Coating materials for FBG sensors are developed using advanced plasma techniques, different coating compositions and coating thickness will be tested to optimise hydrogen sensitivity.
The correct selection of base sensor materials (like metal oxide semiconductor in combination with precious metals) and deposited with an optimized composition can lead an increased H2 sensibility. For that purpose, significant modifications of an industrial magnetron sputtering unit have been initiated. This included the selection and installation of crucial hardware elements, such as adapted size magnetrons and an external power supply. A series of coating deposition were performed and examined through scanning electron microscopy. The influence of the coating characteristics on the performance of the sensors will be studied at a lab scale in a specifically designed H2 chamber, controlling variables like temperature, humidity and hydrogen concentration. For the lab tests of the solution, a aboratory test chamber was developed. Given the high importance of safety measures at this stage, ta contingency plan to address potential failures during testing.
The development of FBG interrogators is also being performed, the aim is to allow a system that can integrate a large number of measurement points with a single interrogator maintaining an optimal response time. A dedicated software is being developed, that will receive, process and provide real-time verification of the signals streamed from three different detection technologies and corresponding interrogators: FBG, acoustic and temperature sensing. The first tests for the deployment of the combined system merging different technologies have taken place.
Once the coatings, interrogators and software are ready, validation will take place for pre-defined use cases, such as pipelines, Hydrogen Refueling Stations and gas grid installations. The initial validation plan for the tests has been developed, and the consortium will work in a detail test protocol in the next months. There will be two round of tests at each of the three installations, to ensure the learnings in the first round are incorporated in the final validation.
Progress has also taken place in the development of sensor solutions. Coating materials for FBG sensors are developed using advanced plasma techniques, different coating compositions and coating thickness will be tested to optimise hydrogen sensitivity.
The correct selection of base sensor materials (like metal oxide semiconductor in combination with precious metals) and deposited with an optimized composition can lead an increased H2 sensibility. For that purpose, significant modifications of an industrial magnetron sputtering unit have been initiated. This included the selection and installation of crucial hardware elements, such as adapted size magnetrons and an external power supply. A series of coating deposition were performed and examined through scanning electron microscopy. The influence of the coating characteristics on the performance of the sensors will be studied at a lab scale in a specifically designed H2 chamber, controlling variables like temperature, humidity and hydrogen concentration. For the lab tests of the solution, a aboratory test chamber was developed. Given the high importance of safety measures at this stage, ta contingency plan to address potential failures during testing.
The development of FBG interrogators is also being performed, the aim is to allow a system that can integrate a large number of measurement points with a single interrogator maintaining an optimal response time. A dedicated software is being developed, that will receive, process and provide real-time verification of the signals streamed from three different detection technologies and corresponding interrogators: FBG, acoustic and temperature sensing. The first tests for the deployment of the combined system merging different technologies have taken place.
Once the coatings, interrogators and software are ready, validation will take place for pre-defined use cases, such as pipelines, Hydrogen Refueling Stations and gas grid installations. The initial validation plan for the tests has been developed, and the consortium will work in a detail test protocol in the next months. There will be two round of tests at each of the three installations, to ensure the learnings in the first round are incorporated in the final validation.
To ensure success of the technology under development, we have identified the following key needs:
• Demonstration projects: to consider the importance of demonstration projects to validate the technology in real-world settings. This will be important to showcase the effectiveness of the system to potential stakeholders.
• Access to markets and finance to support commercialization efforts: securing funding to gain market access is essential in the first steps of commercialization and production scale-up.
• Intellectual property rights (IPR) support: to protect innovations through strong IPR support is key to ensure competitiveness in the market.
• Regulatory and standardization frameworks: ensuring compliance will facilitate interoperability and will build trust among potential users.
• Demonstration projects: to consider the importance of demonstration projects to validate the technology in real-world settings. This will be important to showcase the effectiveness of the system to potential stakeholders.
• Access to markets and finance to support commercialization efforts: securing funding to gain market access is essential in the first steps of commercialization and production scale-up.
• Intellectual property rights (IPR) support: to protect innovations through strong IPR support is key to ensure competitiveness in the market.
• Regulatory and standardization frameworks: ensuring compliance will facilitate interoperability and will build trust among potential users.