Hydrogen Technology Expo in Bremen October 2022. Central cooling systems for green hydrogen production plants. Dry cooling, wet cooling and adiabatic cooling. Production capacity bigger than 100MW. PEM electrolysis and alkaline water electrolysis.

1. Roy Niekerk
Kelvion Thermal Solutions
THERMAL MANAGEMENT IN
GREEN HYDROGEN
PRODUCTION: DESIGN
CONSIDERATIONS

2. Experts in heat exchange – Since 1920
OUR VISION & VALUES RESEARCH & DEVELOPMENT
YOUR ADDED VALUES
WE ARE ONE
GLOBAL
KELVION
ONE
KELVION
WE ARE
CUSTOMER
DRIVEN
CUSTOMER
DRIVEN
WE ARE OPEN
AND
TRANSPARENT
TRANSPARENT
WE KEEP OUR
COMMITMENTS
COMMITTED
WE LEAD BY
EXAMPLE
LEAD
BY
EXAMPLE
HEAT X-CHANGING THE WORLD WITH
SUSTAINABLE ENGINEERED SOLUTIONS
On Time
Delivery
Global
Supply Options
Emissions
Reductions
Energy
Efficiency
Execution
Reliability
Production
Capacity
R&D
Experts
Innovative
Solutions
Commercial
Competitiveness
Innovative Kelvion Technologies (Excerpt)
► DIESTA Tube
► Groovy Tube
► CW Tube
► Standardized Solutions
2

3. Our Manufacturing And Service
Capabilities
3
BRAZIL
Franco da Rocha
► Air Fin Coolers Alu
► Shell & Tube
CHINA
Changshu
► Air Cooled Condensers
► Air Fin Coolers Alu
► Air Dryers & Economizers
► Shell & Tube
FRANCE
Nantes (Service)
Air Fin Coolers Alu
► Diffusion Bonded Heat Exchangers
NETHERLANDS
Doetinchem
► Closed-Loop Cooling Towers
► Modular Cooling Towers
POLAND
Opole
► Air Dryers & Economizers
► Air Fin Coolers Alu
► Air Fin Coolers HDG
► Desublimators
► Welded Plate Heat Exchangers
► Shell & Tube
SPAIN
Igorre
► Air Fin Coolers HDG
UNITED STATES
Catoosa
► Air Fin Coolers Alu
► Air Dryers & Economizers
QATAR
Doha (Service)
► Air Cooled Condensers
► Air Fin Coolers
► Shell & Tube
SOUTH AFRICA
Germiston (Service)
► Air Fin Coolers
► Cooling Towers
► Shell & Tube
MANUFACTURING SITES SERVICE HUBS
MANUFACTURING SITES SERVICE HUBS
OUR MANUFACTURING AND
SERVICE CAPABILITIES

4. Kelvion Thermal Solutions
KTS H2 SOLUTIONS
FROM PRODUCTION TO
DISTRIBUTION

5. CENTRAL COOLING SYSTEM
5
Air Fin Cooler
Cooling Tower
Water
Tank
KOH
Tank
Lye
Cooler
Gas
Cooler
Gas
Cooler
H2 O2
Circulation
Pump
AEC
Gas
Separators
Gas
Coolers
Lye
Cooler
Alkaline electrolysis process
Heat to be dissipated with central cooling
system using Air Fin Cooler or Cooling Tower

6. IDEAL FOR MEDIUM AND LARGE SCALE
6
Air Fin Cooler
Cooling Tower
Electrolysis
cell 1
It is a perfect solution for large scale up electrolyzer
plants, resulting with smallest footprint, lowest fans
number and highest efficiency.
Electrolysis
cell 2
Electrolysis
cell 3
Electrolysis
cell 4
Electrolysis
cell 5
Electrolysis
cell 6
(…)

7. OPTION 1: CENTRAL COOLING – AIR FIN COOLER
7
Basis
⊲ Capacity 1 MW to 7500 MW
⊲ Application: Water / Water Glycol
or hydrocarbons
⊲ Applicable to all regions
⊲ Minimum approach temp. 7°C
⊲ Humidification system can apply
when water is available
COOLER DESIGN HINTS
Groovy Finned
Tubes
2 to 4 large fans
and motors per
bay
Optimized installed
motor power with
Groovy/DIESTA
Bundles and bays
designed as per plot
requirements
Plot restrictions can
drive the design
Reduction of CO2
emissions

8. AIR FIN COOLER – DIESTA TUBE / GROOVY FINS
8
FIN SHAPE
⊲ Reducing “dead zone” by air guidance
⊲ Increasing turbulences on tube and air
sides
⊲ More than 20% increase of air side heat
transfer coefficient at equivalent fan
power
Kelvion
patented
technology
Smaller
units
Over 5000
bundles installed
worldwide

9. OPTION 2: CENTRAL COOLING – COOLING TOWER
9
Basis
⊲ Capacity 0.5 MW to 100 MW per cell
⊲ Application: cooling Water utilities
⊲ Applicable to all regions
⊲ Minimum approach temp. 2°C
(considering wet bulb temperature)
COOLER DESIGN
1 to unlimited fans
QTY (1 per cell)
Less fan power
consumption than
Dry cooling
system
Lowest CAPEX
HX solution
Optimized HX
footprint

10. OPTION 2: CENTRAL COOLING - COOLING TOWER
PRINCIPLE EVAPORATIVE COOLING
10
► Evaporative cooling is natural process using water as cooling medium
► Transferring “waste” heat by sacrificing 1% water flow into the atmosphere
► Working principle in open counter flow (picture), open cross-flow or closed loop (water cooling an internal tube bundle)
► Pre-assembled or field-erected
Open Loop Closed Loop TUNDRACEL

11. PAD SYSTEMS & SPRAY
SYSTEMS
(ADIABATIC COOLING)
11

12. WARM & DRY AIR
COOL & HUMID AIR
WHAT IS ADIABATIC?
12
Adiabatic cooling is the process of
reducing temperature through a
change in air humidity
To evaporate water, energy in form of
heat is required. This evaporation
energy is extracted from the ambient air
which cools it.

13. ADIABATIC PRINCIPLE
13
Remember how cold it is when you get out of
the pool wet on a dry, hot but windy day and
dry your skin in the air
CHILL
You immediately
feel the cooling of
the skin through the
evaporation.
SWIM
After a nice swim on a
hot sunny day
WIND
The wind evaporates
the water

14. WET COOLING | APPLICATIONS
14
HIGH PEAK OFFSET SAFETY
The process have to run
evertime!
WET
COOLING
Reduced
Footprint
Higher
Efficiency
Enhanced
Capacity
Prolonged
Free
Cooling
Improved
Partial Free
Cooling
Fan Power /
Noise
REDUCED FOOTPRINT
Greater approach =
same capacity in smaller footprint
HIGHER EFFICIENCY
Less Fan Power = Less Fan
Noise
ENHANCED CAPACITY
Maximise capacity by increasing
approach
PROLONGED FREECOOLING & IMPROVED PARTIAL FREE COOLING
Increased number of freecooling hours / year
Less hours of mechanical cooling / year
APPLICATIONS
In climates with high ambient temperatures, air-cooled heat exchangers require:
► too much capital cost
► consume too much energy
► require too much plan area
In many cases, incorporating adiabatic pads or spray system on an air-cooled heat exchanger is the best
solution to balance costs, energy consumption and the size or number of units required.

15. THE SPRAY SYSTEM
15

16. 16
Spray system :
The purpose of the fogging/Spray system is to relieve the air-cooler by
decreasing the air inlet temperature.
The fogging/Spray system is comprised of a high-pressure skid located at
grade and nozzle lines are installed below the finned tube bundles.
The nozzles produce an atomized spray that instantly evaporates into the air,
which in turns reduces the air inlet temperature.
The main requirements to install a fogging system are the following:
• Demineralized water or at least soft water (inlet pressure in between 3
and 5 bars),
• Electrical power (in between 11 and 55kW per skid)

17. SPRAY SYSTEM:
17
One High pressure skid including :
▪ high pressure pumps with unloader valve located.
▪ motors with standard coating
▪ Pressure gauge, 0-160 barg
▪ Low pressure solenoid valve – SS valve body
▪ Pressure switches
▪ Filters
▪ Electrical cabinet including Crouzet PLC
▪ One Probe (ambient temperature and relative
humidity).
▪ 316L Stainless steel Nozzle lines from high
pressure group up to the air-cooler fan deck.
▪ Reinforced flexible hoses from skid outlet to tubes.
▪ nozzles

18. 18
KELVION FOGGING INSTALLATION: SAUDI ARABIA 2017 -
SOLUTION

19. THE ADIABATIC PADS SYSTEM
19

20. ADIABATIC PAD SYSTEM:
20
The basic principle for any air-pre-cooling system is to reduce the air dry-bulb temperature entering the
bundle. The figure illustrates a basic arrangement where water is distributed over the entire adiabatic
pad plan area to saturate the adiabatic media.
Ambient air passing through the wetted adiabatic pad increases in moisture content (i.e. increased
relative humidity), cooling the entering air dry-bulb temperature toward the entering air wet-bulb
temperature. The lower dry-bulb temperature exiting the adiabatic pad is referred to as the depressed
dry-bulb.
In an adiabatic fluid cooler, the pre-cooled air with depressed dry-bulb travels through the tube and fin,
offering a substantial increase in heat rejection capability.

21. ADIABATIC PAD SYSTEM:
21
Adiabatic pad manufacturers express the pad’s ability to achieve an
exiting air dry-bulb temperature for a known entering air dry and wet-
bulb temperature as saturation efficiency. The dry-bulb temperature
exiting the adiabatic pad media is calculated using Equation below.

22. ADIABATIC PAD SYSTEM:
22
BOOST PRESSURE WITH PROTECTION
INCLUDES:
• ON / OFF SOLENOID
• UV LAMP
• PUMP
• CONTROLLER
*UV LAMP REDUCES LEGIONELLA RISK

23. THE COMPARISON:
- SPRAY SYSTEMS
- PAD SYSTEMS
- AIR FIN COOLER
- COOLING TOWERS
23

24. CASE: GREEN HYDROGEN WESTER-EUROPEAN LOCATION
► Green hydrogen plant capacity 100 MW
► Design capacity central cooling system 32 MW
► Dry / Wet Bulb Temperature: 30°C / 21°C
► Spray system Switch on Temperature is 23°C
► *Based on a COC of 4 which depends on
make-up water quality
24
What is the goal?
• Aiming on lowest
plotplan?
• Amining at lowest
process temperature?
(knock-out maximum
water before drying
section)

25. APPROACH TEMPERATURE
► Rules of thumb on approach temperature:
▪ AFC 10°C to dry bulb
▪ Special AFC (Groovy & Diesta) 7°C to dry bulb
▪ Cooling tower 4°C to wet bulb
▪ Plate & Frame exchanger 2°C
► Groovy AFC cooling with 30°C dry bulb. Closed loop
37°C. Adding 2°C P&F results in 39°C minumum process
temp
► Cooling tower, wet bulb temp 21°C. CT water 25°C. Add
2°C in P&F, closed loop at 27°C. Add another 2°C P&F,
results in 29°C minimum process temp
25
Approach
temperature

26. COMPARING DRY, SPRAY, PADS AND WET – OPTIMIZE PLOTPLAN
Air Fin Cooler Air Fin cooler with
spray system
Air Fin cooler with
adiabatic pads
Cooling Tower
Installation 12 bays, 2 bundles per bay
tube length 15
6 bays, 2 bundles per bay
tube length 15
6 bays, 2 bundles per bay
tube length 15
4 cells
8.7m x 8.7m
Min achievable process temp 39°C 39°C 39°C 29°C
Number of fans 36 18 18 4
Total plot space 80 x 15 m (1200 m2) 40 x 15 m (600 m2) 40 x 15 m (600 m2) 8.7m x 37.8m
Installed motor power 1330 kW 666 kW 900 kW 300 kW
Annual electrical consumption 100% 50% 70% 25%
Annual Evaporated water amount zero 6 395 m3 6 395 m3 385 440 m3
Annual Water usage* zero 6 395 m3 8 527 m3 514 212 m3
CAPEX factor 100% 65% 85% 25%
*Based on a COC of 4 which depends on make-up water quality
Green hydrogen plant capacity 100 MW - Design capacity central cooling system 32 MW
Dry / Wet Bulb Temperature: 30°C / 21°C
Spray system Switch on Temperature is 23°C
26

27. COMPARING DRY, SPRAY, PADS AND WET – MINIMIZE PROCESS TEMP
Air Fin Cooler Air Fin cooler with
spray system
Air Fin cooler with
adiabatic pads
Cooling Tower
Installation 12 bays, 2 bundles per bay
tube length 15
12 bays, 2 bundles per
bay
tube length 15
12 bays, 2 bundles per bay
tube length 15
4 cells
8.7m x 8.7m
Min achievable process
temp
39°C 31.5°C 31.5°C 29°C
Number of fans 36 36 36 4
Total plot space 80 x 15 m (1200 m2) 80 x 15 m (1200 m2) 80 x 15 m (1200 m2) 8.7m x 37.8m
Installed motor power 1330 kW 1330 kW 1725 kW 300 kW
Annual electrical
consumption
100% 102% 130% 25%
Annual Evaporated water
amount
zero 10 924 m3 10 924 m3 385 440 m3
Annual Water usage* zero 10 924 m3 14 565 m3 514 212 m3
CAPEX factor 100% 115% 140% 25%
*Based on a COC of 4 which depends on make-up water quality
Green hydrogen plant capacity 100 MW - Design capacity central cooling system 32 MW
Dry / Wet Bulb Temperature: 30°C / 21°C - Spray system Switch on Temperature is 23°C
27

28. www.kelvion.com
CONTACT
©2018
Kelvion
Holding
GmbH.
All
rights
reserved.
Roy Niekerk
+31 6 50 879 284
Roy.Niekerk@Kelvion.com

29. ©2021
Kelvion
Holding
GmbH.
All
rights
reserved.