Periodic Reporting for period 1 - HyCoFlex (Hydrogen for Cogeneration in Flexible operation)
Période du rapport: 2024-02-01 au 2025-09-30
The HyCoFlex project develops a retrofittable solution package enabling existing cogeneration plants to operate on up to 100 % hydrogen; therefore operating with zero CO2 emissions . It aims to demonstrate a decarbonised, highly flexible combined heat and power (CHP) plant using an upgraded Siemens Energy SGT-400 gas turbine at an industrial site in Saillat-sur-Vienne, France.
Building on the HYFLEXPOWER project, HyCoFlex advances a fully integrated “power-to-hydrogen-to-power” concept. The project combines advanced Dry Low Emission combustion technology, upgraded hydrogen infrastructure and dynamic digital modelling, simulation and optimisation tools to prove the technical, environmental and economic feasibility of hydrogen-based cogeneration plants. HyCoFlex will demonstrate operational flexibilityof power generation with low NOx emissions and cost-efficient hydrogen generation, supporting Europe’s industrial decarbonisation and energy transition goals.
Building on the HYFLEXPOWER project, HyCoFlex advances a fully integrated “power-to-hydrogen-to-power” concept. The project combines advanced Dry Low Emission combustion technology, upgraded hydrogen infrastructure and dynamic digital modelling, simulation and optimisation tools to prove the technical, environmental and economic feasibility of hydrogen-based cogeneration plants. HyCoFlex will demonstrate operational flexibilityof power generation with low NOx emissions and cost-efficient hydrogen generation, supporting Europe’s industrial decarbonisation and energy transition goals.
During the first reporting period, the consortium completed comprehensive safety studies confirming robust risk management for 100 % H2 operation and obtained the necessary authorisations from French authorities. Modification and maintenance works on the mixing station and plant infrastructure were finalised, ensuring readiness for the 2025 demonstration campaign.
A performance gap analysis based on the HYFLEXPOWER test resultsin 2023 identified improved flashback resistance at constant NOx as a primary design target , along with improved mixing station flow control. High-pressure tests at the Siemens Energy combustion test facility Clean Energy Center (CEC) validated upgraded combustor hardware, confirming substantial progress toward emission and stability goals.
The upgraded mixing-station control was tuned for stable operation under dynamic hydrogen/natural-gas blends. Tests successfully demonstrated ramp-rate capability above 10% power/min and tolerance to ±30 % vol hydrogen fluctuations . The flashback-detection system was verified, preventing hardware damage.
Dynamic simulation and optimisation models were developed to link hydrogen demand in the cogeneration unit with real-time electricity prices, enabling the determination of optimal electrolyser dispatch strategies and capacity sizing, with resulting Levelized Cost of Hydrogen (LCOH) around 5 €/kg. Optimal electrolyser sizing is highly sensitive to the maximum allowable hydrogen blending ratio of the cogeneration plant. An electrolyser dimensioned for 100% H2 blending is not economically or operationally optimal when the system operates under 50% H2 blends.
A performance gap analysis based on the HYFLEXPOWER test resultsin 2023 identified improved flashback resistance at constant NOx as a primary design target , along with improved mixing station flow control. High-pressure tests at the Siemens Energy combustion test facility Clean Energy Center (CEC) validated upgraded combustor hardware, confirming substantial progress toward emission and stability goals.
The upgraded mixing-station control was tuned for stable operation under dynamic hydrogen/natural-gas blends. Tests successfully demonstrated ramp-rate capability above 10% power/min and tolerance to ±30 % vol hydrogen fluctuations . The flashback-detection system was verified, preventing hardware damage.
Dynamic simulation and optimisation models were developed to link hydrogen demand in the cogeneration unit with real-time electricity prices, enabling the determination of optimal electrolyser dispatch strategies and capacity sizing, with resulting Levelized Cost of Hydrogen (LCOH) around 5 €/kg. Optimal electrolyser sizing is highly sensitive to the maximum allowable hydrogen blending ratio of the cogeneration plant. An electrolyser dimensioned for 100% H2 blending is not economically or operationally optimal when the system operates under 50% H2 blends.
HyCoFlex advances the state of the art in hydrogen-fuelled cogeneration by delivering a fully integrated, validated and safe plant concept that goes well beyond prior single-cycle demonstrations. Once completed, the project will have introduced several technological and methodological innovations:
• Advanced hydrogen combustion system: development of a Dry Low Emission combustor capable of stable operation across the full range of NG/H2 blends with 0–100 % H2 while keeping NOₓ below 25 ppmv @ 15 % O2;
• Flexible cogeneration plant operation: proven capability for rapid load changes (> ±10 % load/min) and resilience to ± 30 % H2 fluctuations, ensuring grid-supporting flexibility and reliability;
• Integrated control and safety framework: extension of hydrogen safety concepts from the gas-turbine package to the entire cogeneration system, including the Heat Recovery Steam Generator (HRSG) and auxiliary systems;
• Digital twin and dynamic optimisation tools: coupling of process models with economic optimisation to define cost-optimal dispatch strategies and assess scalability to larger industrial sites;
• Additive-manufactured burner components: validation of 3D-printed hardware for hydrogen operation, reducing lead time and cost while enabling performance.
These achievements position HyCoFlex to reach TRL 7 through the upcoming engine demonstrations, enabling future replication and commercial deployment in industrial and utility-scale cogeneration applications. The outcomes will provide critical input for future hydrogen combustion standards and certification frameworks in Europe.
• Advanced hydrogen combustion system: development of a Dry Low Emission combustor capable of stable operation across the full range of NG/H2 blends with 0–100 % H2 while keeping NOₓ below 25 ppmv @ 15 % O2;
• Flexible cogeneration plant operation: proven capability for rapid load changes (> ±10 % load/min) and resilience to ± 30 % H2 fluctuations, ensuring grid-supporting flexibility and reliability;
• Integrated control and safety framework: extension of hydrogen safety concepts from the gas-turbine package to the entire cogeneration system, including the Heat Recovery Steam Generator (HRSG) and auxiliary systems;
• Digital twin and dynamic optimisation tools: coupling of process models with economic optimisation to define cost-optimal dispatch strategies and assess scalability to larger industrial sites;
• Additive-manufactured burner components: validation of 3D-printed hardware for hydrogen operation, reducing lead time and cost while enabling performance.
These achievements position HyCoFlex to reach TRL 7 through the upcoming engine demonstrations, enabling future replication and commercial deployment in industrial and utility-scale cogeneration applications. The outcomes will provide critical input for future hydrogen combustion standards and certification frameworks in Europe.