Modular Processing Facilities for Hydrogen and Other Modular Processing Solutions

The civil construction industry is undergoing a significant transformation towards off-site construction methods to streamline operations and enhance project efficiency.

Among these methods, modular construction has emerged as a leader because it allows components to be prefabricated in controlled environments away from traditional construction sites.

Modular processing plants illustrate this trend, providing a versatile solution for various industrial applications. By prefabricating essential components such as structural frameworks, equipment, and systems off-site, these plants not only expedite construction schedules but also ensure superior quality control and safety standards.

This article explores the transformative impact of modular processing plants across diverse sectors. From energy and manufacturing to pharmaceuticals and beyond, these plants are revolutionizing project execution by offering scalable, adaptable, and environmentally sound solutions.

WHAT ARE THE BENEFITS OF MODULAR PROCESSING?

ACCELERATED SCHEDULES 

By constructing processing units in controlled shop environments, project timelines can be significantly reduced compared to on-site construction. This approach minimizes or eliminates challenges such as weather delays, permitting issues, work stoppages, and logistical constraints like crane availability. Typically, the fabrication of a complete stainless or carbon steel modular process unit, from receiving a purchase order to delivery, takes approximately 7-8 months. This timeline encompasses all stages, from initial engineering and design through to final assembly and testing.

COST EFFECTIVENESS 

Modular processing plants offer substantial cost savings of 25–30% compared to traditional construction methods. Moreover, modular systems provide firm, lump-sum quotes, ensuring financial predictability and transparency throughout the project.

VERSATILITY 

Modular units are highly versatile, functioning effectively both indoors and outdoors. They can be easily customized and enclosed with walls to protect operational equipment and personnel from adverse weather conditions. This flexibility also allows for discreet placement of process components, ensuring confidentiality from neighboring entities and competitors.

PERMIT-FRIENDLY CONSTRUCTION 

Modular processing enables construction to proceed while waiting for permits, offering flexibility and efficiency in project timelines.

HYDROGEN POWER AND THE FUTURE OF ENERGY

Hydrogen power presents a promising solution for reducing carbon emissions in electricity and transportation. It serves dual roles by storing energy and fueling hydrogen fuel-cell vehicles—such as cars, trains, ships, and planes.

The concept of a hydrogen economy offers a compelling alternative to fossil fuel-based energy sources.

For example, hydrogen-powered vehicles use fuel cells to convert gas into electricity, providing a zero-emissions footprint similar to electric vehicles but without the environmental drawbacks associated with battery banks—like long charging times and limited range. Currently, however, the vast majority of hydrogen production comes from fossil fuels rather than carbon-free sources.

Approximately 95% of the world's hydrogen is produced through processes like steam methane reforming, which involves pressurizing a steam and methane gas mixture with a nickel catalyst, resulting in hydrogen, carbon monoxide, and some carbon dioxide. Scaling up clean hydrogen production is crucial to meeting global transportation fuel demands sustainably.

MODULAR CONSTRUCTION FOR HYDROGEN POWER AND GREEN ENERGY

What are some practical applications of modular plants?

One application stands out for its potential to make a global impact.

NuScale Power has unveiled findings from a recent study demonstrating how a single small nuclear NuScale Power Module (NPM) could enable cost-effective production of nearly 50 tons of hydrogen fuel per day.

Conducted by the Idaho National Laboratory, the study reveals that NuScale Power Modules (NPMs) now yield 20% more hydrogen from water due to enhanced power output. NuScale asserts that its process is economically viable, leveraging nuclear reactors that simultaneously produce hydrogen and electricity.

These compact modular reactors can seamlessly transition between hydrogen production and electricity generation to meet varying demand levels. Based in Oregon, NuScale estimates that a single NPM could reduce annual carbon dioxide emissions by 168,000 tonnes. Each 250 MWt NuScale module can generate 2,053 kg of hydrogen per hour, amounting to nearly 50 metric tons daily.

At current U.S. consumption rates, one NPM could provide enough hydrogen to power 38,000 fuel-cell cars or 1,500 long-haul fuel-cell trucks annually. NuScale's innovative design incorporates a multi-module power plant with integrated steam bypass, enabling clean electricity generation for the grid while efficiently producing hydrogen during periods of low electricity demand.

This hydrogen can be stored for future energy needs or used to fuel a variety of emissions-free vehicles, including cars, trucks, trains, ships, and aircraft.