Power-to-X plant, Kassø, Denmark

Why We Committed to the Project

The emergence of e-fuels as a sustainable energy source is transforming the global energy landscape, and 2JCP intends to be at the heart of this transformation. Proof of our commitment to advancing clean energy solutions is our recent assignment in the Danish town of Kassø, where, in partnership with Siemens Energy, we are partaking in a pioneering project focused on e-methanol production for European Energy A/S.

E-methanol offers an efficient solution to challenges related to hydrogen storage and represents the future of energy for aircraft, ships (Maersk cargo ship fleet in our case), and trains. In this project, hydrogen is produced on-site and subsequently converted to e-methanol, which can be easily transported. Lego and Novo Nordisk are also among the planned users of e-methanol produced in Kassø.

How We Contributed to the Project

The electrolyzer used in this project, the Siemens Silyzer 300, utilizes PEM (Proton Exchange Membrane) electrolysis – a sophisticated form of electrolysis with high efficiency. These electrolyzers are among the first industrial-scale electrolyzers to be deployed, marking a significant milestone in the energy industry.

For 2JCP, the premier partner of Siemens Energy in the packaging of Silyzer 300 electrolyzers, this project represented our first notch in the hydrogen sector. 2JCP was responsible for packaging of three 17.5 MW Silyzer 300 units that will be used in the Kassø project. Siemens Energy delivered the electrolyzer stacks and the heat exchangers to Račice, while the rest was entirely up to 2JCP. This ranged from detailed engineering of the entire equipment, the design of gas separation vessels, through to the manufacture of individual components (mix of carbon and stainless steel) and the assembly of all components into a functioning system, including electrical installation.

"This is a pilot project to test the entire cycle, to verify that the required amount of hydrogen can be produced and that it can be reliably used to power ocean vessels. We are handing over the first order this March and, as we are a key partner of Siemens Energy for this project, we believe that the planned 20-fold increase in production capacity in Phases 2 and 3 will also significantly benefit us," says Jan Pačes, founder of 2JCP and Managing Director of the Power & Process Systems division.

Many things had to be recalibrated or invented from scratch at 2JCP for the successful production of the Silyzers. Siemens Energy placed extreme demands on the cleanliness of input components and the entire manufacturing environment. We also learned to work even better with pipe welding, and invested in several orbital welding machines for the Silyzer production. Last but not least, cleaning the entire system and filling it with demineralized water for future transport posed a significant challenge.

The knowledge gained during the project, both in the office and in the workshop, is crucial for successfully handling similar orders in the future. In April 2023, a one-day workshop was held between 2JCP and Siemens Energy experts, where both parties exchanged experiences and insights. This further deepened the partnership between the two companies in the production of Silyzer 300 units.

First Maersk's e-methanol powered cargo ship is already completed, more are in production.

Visualization of the new Power-to-X plant in Kassø, Denmark.
© European Energy

Completed Silyzer 300 hydrogen electrolyzer before shipping to Kassø.

More About the Project

In Kassø, a small town in Denmark, Siemens Energy is helping to build a special facility for the production of green hydrogen and e-methanol. The project is based on the technology of electrolytic hydrogen production from renewable energy sources, with the hydrogen, in combination with captured CO2 from the atmosphere, being used for the synthetic production of e-methanol.

A significant driver for this project is the existing surplus capacity of wind energy in Denmark, which amounts to approximately 3 GW. The country has been utilizing 100% renewable energy sources for several years and continues to invest in this sector, leading to a clear surplus of wind energy that is used to power green hydrogen production.

The hydrogen produced in Kassø and converted to e-methanol will be primarily used to power Maersk's cargo ships. Maersk plans to use e-methanol as a sustainable fuel for its ships and aims to achieve emission neutrality in its operations by 2030. The first two e-methanol ships are already in production and will be operational in 2024, with another four ordered at the beginning of 2022 and due to be delivered in May 2025. According to Maersk, the ships will be 350 meters long and 53.5 meters wide and are designed, unlike any other large-capacity cargo ships in the past.

The success of this project will represent a significant leap forward in sustainable maritime transportation, as shipping companies have indicated they are willing to pay 20-30% higher costs for environmentally friendly ships. Given that the EU plans to impose a carbon tax on ships in European ports, the importance of such initiatives is growing.

The Danish Green Investment Fund (DGIF) is investing 53 million euros into this project, and the European Union, as part of its Important Projects of Common European Interest (IPCEI) cooperation, is investing another 80 million euros.

The project timeline envisages the facility's completion in 2023, followed by testing and production startup. The project forms part of Denmark's broader plan to achieve climate goals, which includes the development of renewable energy sources and the reduction of greenhouse gas emissions in various industry and transport sectors.

MORE CASE STUDIES

With a strong legacy in energy products, we are constantly moving towards cleaner energy solutions.

Turnkey delivery of a renewable gasification plant (coming soon)
Sofidel, Kisa plant, Sweden

Upgrading power plant's existing filterhouse with an inlet chilling technology (coming soon)
Redhawk power plant, Arizona, USA

Delivery of special-purpose storage and process tanks for an offshore HVDC station (coming soon)
Sunrise Wind offshore farm, New York, USA

Our Approach

We have grown through a combination of engineering know-how, courage, common sense and the proven skills of our workers. We are the bridge between thinking and making, between an idea and a multi-ton product, between our generation and the next.

Engineering and innovations

Many of our works delivered around the world were the first of their kind, whether they were components of drilling systems or green methanol production solutions. We have always tended to be co-creators of engineering solutions, never giving up on any technological challenge.

Whatever can be invented can be manufactured.

Manufacturing and delivery

Our roots are in the welding shop where it all began thirty years ago. We know well enough about steel to make it work perfectly for the energy projects of the future.

We also know that even a well-made component is useless until it's delivered, up and running. That's why we handle the entire product lifecycle - from design to go-live.