Engineering Hydrogen Solutions

Key things to know about hydrogen sulfide

Hydrogen sulfide (H2S) gas can be fatal at high concentrations. But even low concentrations can cause health issues, particularly with prolonged exposure. So how can you best protect workers and minimise downtime? We answer your common questions about H2S.

What is H2S gas?

Hydrogen sulfide is a highly flammable, toxic and corrosive gas found in several industries including oil and gas, wastewater and chemical processing. It’s sometimes called ‘sour gas’, ‘sewer gas’ or ‘stink damp’ because of the way it smells like rotten eggs. However, H2S can’t reliably be detected by smell as it quickly deadens the sense of smell (a process known as ‘olfactory desensitisation or fatigue’).

How dangerous is H2S?

Exposure to high levels of H2S can be fatal, leading to loss of breathing, coma, seizures and death. It’s the second most common cause of fatal gas inhalation exposure in the workplace, second only to carbon monoxide^[1].

But H2S can also be harmful at low concentration levels, causing headaches, dizziness, nausea, breathing difficulties and a sore throat. These health impacts can become more serious with prolonged exposure.

Low concentration vs. high concentration H2S – exposure limits

The health impacts of H2S depend on how much is inhaled and for how long. The recommended exposure limit set by NIOSH (the US National Institute for Occupational Safety and Health) for ten minutes is 10 ppm^[2]. However, some U.S. states have developed ambient air standards for H2S well below OSHA and NIOSH standards due to concerns about health risks from chronic exposure^[3].

For longer exposures to H2S, the recommended limits are a lot lower. For example, if you’re exposed for up to 24 hours, the World Health Organisation (WHO) recommends a maximum exposure of 0.1 ppm.

In response to concerns about the risks of H2S to human health even at low concentration levels, some countries have introduced equally stringent guidelines requiring businesses to monitor H₂S at such concentrations. That’s why we’ve recently updated our ALTAIR io™ 4 Connected Gas Detector, offering the option of a low-concentration hydrogen sulfide sensor that can detect H2S at very low levels*.

H2S in industry – the different sector impacts

H2S creates safety challenges for many industries. But some industries are more likely to be affected. These include:

Oil, Gas & Petrochemical (OGP)

OGP facilities handle raw ‘sour’ gas and oil which are naturally high in H2S. Extraction and refining processes release H2S, which may accumulate in confined, poorly ventilated spaces like processing units, pipelines and storage tanks. Closed systems with high-pressure conditions amplify the risks for workers.

Balancing safety and operational efficiency is an ongoing challenge in the OGP industry. Some are tackling this challenge by integrating new technological solutions into their safety management practices.

Waste water management

Wastewater facilities such as closed pipelines and sludge tanks have low oxygen levels and so provide the ideal conditions for H2S buildup. This is because sulfate-reducing bacteria which break down organic material and produce H₂S as a byproduct thrive in anaerobic (low-oxygen) conditions.

One of the key risks for wastewater workers is when they’re entering confined spaces like tanks and sewer lines. For many waste water management businesses, real-time monitoring of gas levels is considered a must-have.

Steel production

The steel industry’s use of high-temperature processes and sulfur-rich materials can lead to the release of H2S, creating hazards for workers. Confined, poorly ventilated spaces and desulfurisation units pose particular risks.

A safety challenge for large steel production facilities can be determining who has used which portable gas detector and when. One company has found a solution to this common problem using the Connected Work Platform driven by ALTAIR io™ 4 connected gas detector.

Preventative measures – safeguarding workers

Given the well-documented risks of H2S to workers, safety managers are seeking out effective preventative measures, including regular training and effective ventilation. The use of Personal Protective Equipment is also important.

But a particularly helpful method for avoiding excessive H2S exposure is constant monitoring by advanced gas detection systems such as our ALTAIR io 4 Connected Gas Detector. Such systems can give you an early warning of even subtle increases in H2S concentration, helping you stay ahead of potential risks. Our updated ALTAIR io 4 device can detect subtle changes in H2S concentration levels at a resolution of 0.1 ppm, offering enhanced protection to workers. The default configuration for low-concentration H2S detection starts at 0.3 ppm, but customers may choose to configure the device to detect H2S starting at 0.0 ppm. This capability is particularly important in industries like oil and gas where companies wish to monitor low levels of H2S. Our low-concentration H2S sensor also offers processes designed to streamline regulatory compliance, minimising downtime and allowing readiness even for large-scale operations.

As with all toxic gases, early detection of H2S is an excellent way to alert safety managers to small increases in H2S emissions so they can help workers avoid harmful exposure, even at low concentrations.

*The default configuration for low-concentration H2S detection on the ALTAIR io 4 connected gas detector starts at 0.3 ppm, but customers may choose to configure the device to detect H2S starting at 0.0 ppm (in increments of 0.1 ppm). 


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^[1] Guidotti TL, 2010. Hydrogen sulfide: Advances in understanding human toxicity. Int. J. Toxicol 29, 569–581. [DOI] [PubMed] [Google Scholar][Ref list]

^[2] https://www.cdc.gov/niosh/npg/npgd0337.html

^[3] https://ohsonline.com/articles/2007/10/human-health-effects-from-exposure-to-lowlevel-concentrations-of-hydrogen-sulfide.aspx

According to Britannica.com. the Bermuda Triangle is a section of the North Atlantic Ocean off North America in which more than 50 ships and 20 airplanes are said to have mysteriously disappeared. Wikipedia goes on to note that in 1952 Fate magazine published "Sea Mystery at Our Back Door", where the author recounted the loss of several planes and ships since World War II. A geography not to be messed with, it seems.

Similarly, in the realm high hazard processing facilities, another challenging geography is the Green Ammonia triangle.

Green Ammonia production is likely to far outweighs the more polluting black, grey or blue production methods, as we transition to a fossil free future. As materials develop, advances in Polymer Electrolyte Membrane (PEM) technology for electrolysers yields greater efficiencies year on year. The route to produce ammonia as a Liquid Organic Hydrogen Carrier (LOHC) brings significant transportation benefits when comparing transportation of liquid H2 in its virgin state.

However, a triangle of significant hazards exists during the ammonia production process, namely:

1. Nitrogen manufactured from an Air Separation Unit, consists of asphyxiant & cryogenic hazards.
2. Hydrogen possesses very low minimum ignition energies (0.017mJ) & has a significant explosive fuel range (4-75% v/v) & will generate a deflagration producing a significant pressure wave (550 bar m/s).
3. The resultant ammonia (produced by the Haber Bosch process) is highly toxic.

At each stage of process design, especially at conceptual, it is imperative to make wise choices of plant/equipment layout. A HAZID study (HS 2) will tease out the safeguard requirements, for example:

• Blast Walls - however an inherently safe design (ISD) may be favoured negating this.
• Spacing of equipment / minimise congestion will help to reduce pressure wave magnitude & assist for equipment inspections or routines. Plant layout is a critical factor not only for constructability but will assist a Reliability Centred Maintenance (RCM) approach and process release of units.

HAZOP (HS 3) must consider an ISD, versus Safety Instrumented Functions which not only need to be appropriately designed (IEC 61511) but maintained for the life of the plant. Any upgrades or changes must be covered by appropriate Functional Safety Audits (FSA’s). DSEAR will need to be followed and adopted prior to final confirmed locations.

Finally, consideration of plant hazards for startup/shutdown must be allowed for, as this is when the plant is at its greatest change of flux. Level-headed decisions need to be made for credible unplanned scenarios, with the appropriate safeguards in place to mitigate any potential loss of containment for any of the plants fluids. Add the hazards of high voltage electrical supply required for the electrolysers into an aqueous rich environment.

In conclusion, the new geography of green ammonia is likely to be a high reward one for those who choose to enter. Just take care to identify the hazards so that your residual risks can be rendered known and low.

Blog by Paul Gornall from Process Safety Matters 

www.processsafetymatters.com

For many years emissions were an unavoidable consequence of industrial development. An increase in consciousness of environmental issues combined with subsequent legislation means that major Oil and Gas companies are under pressure to cut their greenhouse gas emissions and several have responded by setting reduction targets over the coming decades.

There are several ways in which operators can work towards emissions reductions and our focus is on the impact the use of various safety devices can have on this target.

The first point of consideration in this regard should be the safety valves in use. Valves are an obvious place to start as no valve is 100% leak-tight, and this decreases every time there is an activation and the valve re-seats. In the building of new plants, it is a fairly simple solution to specify within the design of the plant a valve with a lower leak rate. However, existing plants are looking at substantial investments to replace older designs with newer technologies. Not a viable economical solution in most cases.

While there have been significant increases in the capabilities of safety valves, they are still not the ideal product when considering future net zero targets. No safety valve is 100% leak-tight and they struggle to meet the exacting requirements of the legislators. An alternative solution is needed.

Although rupture discs have been around for many decades, they are often considered only as secondary relief. To be used where there is a possibility that the safety valve may fail. There is a lack of understanding amongst engineers in industry and a number of myths surrounding the use of rupture discs.

A rupture disc is a non-reclosing device and therefore must be completely replaced when there is an activation. Nuisance downtime leads many operators to associate rupture discs as being problematic whereas if a disc is rupturing frequently there is likely a problem with the process. It is still unrecognized by many operators that when the disc performs correctly it is not the problem, but the solution.

How can a rupture disc help to get improved performance from a safety valve? Rupture discs are 100% leak-tight. By installing a rupture disc in front of a safety valve you get double protection and a solution which can meet emission requirements. There is no more leakage through the safety valve in normal operation and where there is an over-pressure activation, the valve reseats to seal the process once the pressure is vented.

The belief that this arrangement adds more cost into a project has been proven to be false, in fact the opposite is the case. A correctly engineered rupture disc will help lower operating costs and increase the up-time for any plant.

In processes where there is a high concentration of corrosive media, increased temperatures and an operating pressure close to the safety valve set pressure, safety valves are pushed to their limits. Poor performance is common-place. High maintenance costs are needed to keep the valve as close to original specifications as possible, increased downtime to the production for routine valve servicing and/or repairs and higher manpower costs to cover the work scopes.

The solution of the safety valve manufacturers is a higher specification valve, more exotic materials with higher capex costs as well as increased cost of spares to maintain the valves. If you consider a typical petrochemical plant with several hundred safety valves the capital expenditure is significant.

Fig. 1: Rupture disc for isolating safety valves

A rupture disc fitted upstream of the safety valve completely isolates the valve from the process. This protects the safety valve from the process which in turn reduces maintenance requirements. There is also the possibility of reducing CAPAX costs by sourcing a rupture disc and holder in an exotic material and a standard safety valve. The costs of a discs and holder are usually significantly lower than having to source a high specification safety valve which is compatible with the process media.

The protection of safety valves with rupture discs has become increasingly more common in recent years across several industries. However, many operators miss the opportunity to fully protect the safety valve by also isolating the valve from potential corrosion issues on the outlet of the valve.

In many cases, the valve outlet is not a separate discharge line to but is connected to other parts of the plant via a manifold which allows process gases/vapor to enter the outlet of the valve. If there is a risk that the process media can damage the valve via the inlet, this is also the case downstream.

A rupture disc can also be used to isolate the safety valve outlet and prevent any contact with the process media. The rupture disc will also block any back pressure from entering the safety valve and remove those concerns during valve selection.

With burst sensors installed both upstream and downstream rupture discs can be monitored and connected back to the control room for system reporting across the plant, so operators know instantly which valves and discs are in a green or red state.

Another myth surrounding rupture discs is that they can leak. If the disc is to be installed as the primary safety device, that’s to say, without a safety valve behind it, this can be a concern for operators looking to reduce emissions. The majority of leakages via rupture discs are caused by corrosion or damage during installation by mishandling or incorrect torquing. Rupture Disc technology has improved significantly over the years to ensure that damages caused by corrosion or incorrect handling are all but eliminated.  Today’s modern rupture discs no longer use mechanical scoring techniques during manufacturing which can lead to works hardening and corrosion over time.  Advanced manufacturing technologies have resulted in robust rupture discs which are no longer sensitive to torque and virtually immune to damage during installation. Most spurious failures from rupture discs can be avoided by working together with the disc manufacturer to select the ideal rupture disc for the process conditions.

Overall, rupture discs can be used as a cost-effective and efficient way to create a leak-tight process and reduce emissions whether on their own or in combination with a safety valve.

Fig. 2: Ideal combination – safety valve and rupture disc

www.rembe.de

AMSTERDAM, April 9 - 10 – Reuters Events: Hydrogen 2024, the industry's premier executive event, returns to the Leonardo Royal Amsterdam City Hotel, hosting 400 decision-makers to advance hydrogen projects towards financial close by:

• Securing long-lasting offtake commitment
• Securing financing from leading investors
• Reducing production costs
• Integrating cost-effective storage and transportation
• Capturing market share in the $200 billion ammonia opportunity

Joined by 400+ senior decision-makers and budget holders, Hydrogen 2024 promises to be an engaging summit for gaining critical insights on transforming projects into tangible successes. Executives from Statkraft, Uniper, H2 Green Steel take to the stage, providing essential strategies for scalable production while off-stage interactive workshops and networking with BASF, Yara Clean Ammonia and Airbus promises intimate partnership opportunities to build compelling business cases.

In a market rewarding early movers with pivotal learnings and invaluable partnerships, Hydrogen 2024 is where 400 senior directors, manging directors, vice presidents and C-suite executives convene to lift projects off the ground in 2024. With the largest industry players such as Fortescue, Fortum and E.on Gas already confirmed to attend, don’t miss out this April 9-10.

To discover more about Hydrogen 2024, download the brochure here:

For other inquiries, contact: Elijah Cho, Hydrogen Project Director, Reuters Events, This email address is being protected from spambots. You need JavaScript enabled to view it.

About Hydrogen 2024:

Reuters Events: Hydrogen 2024 is the leading executive event in the hydrogen industry, fostering innovation, collaboration, and knowledge sharing to lift projects off the ground. Join us in Amsterdam on April 9-10 to shape the future of the hydrogen industry.

The Hydrogen Awards have been established as an annual measure of enterprise, innovation and excellence – in standards, implementation and thinking about the future and about bringing the use of hydrogen to all industries and sectors and to the public. While the Awards are based in the UK it is now obvious they have international appeal.

The finalist companies for the 2024 awards are listed below.

The results will be announced on February 27 at the Hydrogen Awards Dinner and Ceremony at Keele Hall.

BayoTech
Dubai Electricity Water Authority
Energy Safety Research Institute
First Hydrogen
GenHydro
GeoPura
Gexcon
Giancarlo Zema Design Group
HiiROC

HVS (Hydrogen Vehicle Systems)
Hydrogenscape
IKM Consulting
Johnson Matthey
Mattiq
McHenry Global Industries
Ohmium International
Parker HannifinUK
Toyota Motor Manufacturing

Finalist companies will have the opportunity to receive a category Winner or Award of Merit trophy on stage during the Awards’ presentation. The evening event last year was a huge success and pictures of the 2023 dinner and awards are on the website, including a list of Winners on the  page. The event is expected to attract even greater attendance this year.

Planning to attend the Hydrogen Awards for the second year running, Robert Airey, Market Development Manager – Clean Energy at Parker Hannifin, comments: "With Parker’s 60 years of hydrogen experience we are delighted to not only be one of the named Finalist companies, but also be supporting other top performing companies across the sector as Headline Sponsor to the Hydrogen Awards. Looking at the list of Finalists, the hard work, innovation and dedication is evident as we all push towards enabling a greener energy future.”

Nick Herbert, Luxfer Gas Cylinders sales director:

“It’s inspiring to see a real passion for hydrogen in the automotive sector, and we commend the companies who have demonstrated industry-leading excellence, in order to achieve a shortlisting in this competitive category.  
 
“At Luxfer Gas Cylinders, we are committed to supporting the adoption of hydrogen internationally – our engineers have worked for over two decades building hydrogen systems for a whole range of transport modes, from HGVs, to buses, boats and even drones. 
 
“Alongside a significant legacy in gas storage and transportation, we’re at the very forefront of hydrogen innovation, constantly adapting our trusted technology and applying our vast experience to ensure our solutions reflect how the market is moving. We are proud to be involved in these awards because they represent everything Luxfer stands for – celebrating the journey towards a safe, clean and energy efficient world. We wish these finalists, and fellow pioneers, the very best of luck.”

Headline Sponsors Parker Hannifin  

https://www.parker.com/gb/en/solutions/hydrogen.html

Category Sponsors Luxfer Gas Cylinders

https://www.luxfercylinders.com

Category Sponsors Energy Research Accelerator

https://www.era.ac.uk

Supporting Partners HyDEX

https://hydex.ac.uk">https://hydex.ac.uk

Media Partners

H2 View 

https://www.h2-view.com

Engineering Hydrogen Solutions

https://engineeringhydrogensolutions.com

Places can be booked via the and for more information please contact the event manager This email address is being protected from spambots. You need JavaScript enabled to view it..

Protecting workers and facilities from dangerous hydrogen gas leaks always starts with understanding the standards and taking measures to comply with them.  

For H₂ gas, the international standards for explosion protection include IEC 60079 and IEC 80079, as well as specific standards (ISO 22734 and ISO 19880) for hydrogen facilities. You can delve into the specifics of these and other local standards. Suffice it to say, however, that there are many potential hydrogen-related hazards. 

Which is why we recommend a layered approach to fire and gas protection. By employing several distinct (yet complementary) technologies, facilities can run the detection gamut, including ultrasonic, conventional gas, and flame. 

These technologies may include: 

• Ultrasonic leak detection: Unaffected by wind or plume direction; ideal for monitoring pressured pipes and vessels 
• Point gas detection: Well-suited for low and combustible hydrogen levels; options of catalytic or electrochemical, depending on the protection area 
• Hydrogen flame detection: Best for monitoring infrared (IR) and ultraviolet (UV) radiation; provide a warning to deploy fire suppression and other safety measures 
• Portable gas detection: Enables workers to access areas where sensors are not installed, such as a confined space 

H₂ Safety: Strategies for Planning Detection 

Earlier we established that hydrogen gas presents exciting commercial and sustainability opportunities, as well as several new and distinctive challenges across the production and distribution chain.  

Typically, design, installation, and planning of a layered gas and flame detection system for process industry facilities begins with choosing correct instrumentation for specific potential hazards. It also involves figuring out the particulars, including sensor detection range, mounting, and positioning, field of view, knowledge of lines of sight, and blind spots.  

Because hydrogen gas detection and monitoring poses unique safety challenges, organizations entering (or already engaged in) the hydrogen supply chain should seek guidance from a safety partner like MSA. Through our fire and gas mapping solution, MSA offers hydrogen customers a technical assessment based upon recommendations outlined in the ISA TR84.00.07 Technical Report.  

MSA’s solution delivers: 

• Calculated metrics derived through proprietary mapping software 
• Data-informed mapping report featuring correct placement, scope of gaps in coverage targets, and numerical estimates of detection coverage to increase the likelihood of early detection of hydrogen gas dispersal or fire 
• Quantitative measure of gas detection needs to complement conventional methods based on coverage calculations 

MSA’s proven track record is backed by sector-specific insight and expertise, so we can help you learn more about the safety risks and challenges of hydrogen. 

Ready to dive deeper into hydrogen best practices, safety measures, and detection technologies? Download our Hydrogen Safety white paper or talk to an expert today. 

A Memorandum of Understanding (MoU) has been signed by Brazil’s Ceara state government and GoVerde Energia & Apollo Asset with the aim to produce solar energy and green ammonia at the port of Pecem.

With the expected investment of BRL 3 billion (USD 597.6m/EUR 562m), the project will be implemented in the state’s Pecem Industrial and Port Complex (CIPP), which the government plans to turn into a green hydrogen hub.

GoVerde's New Business Director, Ricardo Junqueira estimates that the planned facility will be capable of producing 40 tonnes per day of green ammonia in the first phase of the project, with another 250 tonnes in the second and another 200 tonnes in the third phase.

With huge ambition and potential, Latin America has an exceptional opportunity to become a global clean hydrogen powerhouse. Clean hydrogen roadmaps have been announced along with an ever-increasing number of projects, both large and small. With ample sun, wind and in some regions, hydro, Latin America can offer affordable clean energy which in turn can offer affordable clean hydrogen.

World Hydrogen Latin America returns for its 2nd annual conference, on December 12-14, 2023

Bringing together over 400 hydrogen experts and professionals, World Hydrogen Latin America explores the biggest challenges and opportunities in the region including:

• Policy, permitting, regulations and certifications for different types of hydrogen
• Discover how to generate local demand and guarantee offtake agreements domestically and internationally
• Scaling-up to giga scale projects for export
• Hydrogen storage and distribution strategies

Delivering pioneering content, interactive training and unique networking opportunities, at World Hydrogen Latin America you will hear from over 100 industry expert speakers including: 

• Paulo Emílio de Miranda, Presidente, Brazilian Hydrogen Association
• Diego Pardow Lorenzo, Minister of Energy, Ministry of Energy Chile
• Walter Verri, Deputy Minister of Industry, Energy and Mining of Uruguay, Ministry of Industry, Energy and Mining
• Diep Nguyen-van Houtte, Senior Manager & Chief Operating Officer, International Finance Corporation
• Rosilena Lindo Riggs, Deputy Secretary of Energy, Secretary of Energy of Panama
• Janina Franco, Senior Energy Specialist, World Bank
• Marcia Maynard, Vice President, Sustainable Energy Development, National Energy Corporation of Trinidad and Tobago Limited
• Carla Primavera, Superintendent – Energy Division, BNDES
• Felipe Diaz, Chief Representative SMBC Chile – Latin America Division, Sumitomo Mitsui Banking Corporation
• Adriana Martin, Executive Director of Innovation and Digital Transformation, Port of Suape
• Luis Sarras, Green Hydrogen Managing Director, International Business, AES Corporation
• Maria Jose Navajas Dominguez, Regional Director - Corfo Magallanes & Chilean Antarctica, CORFO
• Natalia Castilhos, Clean Energy – Latin America, BloombergNEF
• Clara Bowman, Chief Operating Officer, HIF Global
• Emanuel Ramírez, Hydrogen Technical Coordinator, FENOGE

Why World Hydrogen Latin America is the LATAM hydrogen event to attend:

• The event will bring together industry experts from the southern cone of the continent to northern parts of central America including the Caribbean and Mexico.
• Your chance to hear from industry thought-leaders to learn about the latest hydrogen updates & projects in the region and discover tech innovations globally.
• Your opportunity to network with decision makers, projects developers, public sector and more!
• Participate in interactive masterclass sessions and gain more knowledge on specific topics including reducing investment risk, hydrogen derivatives and certification.

Get involved with World Hydrogen Latin America and get in touch with our team today!

See you in Chile. #WHLATAM #WHL