Green Hydrogen Production
Thermal insulation for electrolyser auxiliaries, feed-water and cooling systems, separators, dryers, compressors and process piping where heat conservation, personnel protection or condensation control is required.
Green Hydrogen · Cryogenic Engineering · EPC Support
Green Hydrogen Plant & LH₂ Insulation Engineering
Integrated thermal and cryogenic insulation engineering for electrolyser balance-of-plant, hydrogen purification and liquefaction, liquid-hydrogen storage, vacuum-jacketed transfer lines and associated process equipment.
Electrolyser Balance-of-Plant
Hydrogen Liquefaction
LH₂ Storage
Vacuum & MLI Systems
One integrated thermal boundary
Insulation Engineering Across the Hydrogen Value Chain
The correct system changes with temperature, pressure, duty cycle, environment, equipment geometry and the selected process technology. ERATHERM develops the insulation scope around those interfaces.
Hydrogen Liquefaction
Cold-box interfaces, cryogenic piping, valves, equipment nozzles, penetrations, supports and transitions assessed as a connected heat-leak and vapour-control system.
Storage & Distribution
Engineering support for storage-tank insulation interfaces, vacuum spaces, MLI or selected fill systems, transfer lines, loading connections and boil-off-gas related equipment.
Critical design drivers
LH₂ Insulation Is a System Engineering Problem
At liquid-hydrogen temperature, small geometric discontinuities can become dominant heat bridges. Vacuum performance, support design, contraction, moisture control and installation quality must be considered together.
- Heat-leak and surface-temperature assessment
- Thermal-bridge treatment at supports and penetrations
- Vacuum, MLI and cryogenic insulation interfaces
- Differential contraction and joint movement
- Condensation, icing and atmospheric-liquefaction risk review
- Inspection, maintainability and reinstatement strategy
01
Heat Ingress & Boil-Off
Conductive, convective and radiative paths are assessed so that the insulation concept supports the owner’s heat-leak, boil-off and operating objectives.
02
Vacuum Integrity
Vacuum-space arrangement, MLI installation constraints, getter or adsorbent interfaces and evacuation provisions are coordinated with the responsible vessel or piping OEM.
03
Thermal Contraction
Supports, anchors, bellows, joints and insulation layers are detailed for movement without losing continuity or creating damaging local loads.
04
Safety Interfaces
Insulation details are coordinated with hydrogen detection, ventilation, hazardous-area requirements, relief and vent systems, fire strategy and process-safety decisions.
Fit-for-service selection
Typical Insulation System Architecture
Final materials and thicknesses are selected from project calculations, equipment design, hydrogen compatibility, fire strategy and owner specifications—not from a generic material schedule.
| Asset / Interface | Engineering Objective | Typical System Direction | Critical Checks |
|---|---|---|---|
| Electrolyser auxiliaries | Heat conservation, temperature control and personnel protection | Project-specific hot or cold service insulation with protective cladding | Operating range, water exposure, corrosion control and access |
| Cold gas and process piping | Condensation control and controlled heat gain | Closed-cell or cellular cryogenic systems, vapour barrier and sealed cladding | Permeation, joints, supports, valves and cyclic operation |
| Liquefaction cold-box interfaces | Continuous thermal envelope and low heat ingress | OEM-integrated insulation, selected fill or multilayer concepts | Penetrations, settlement, purging, access and commissioning |
| LH₂ storage interfaces | Minimise radiative and conductive heat leak | High-vacuum space with MLI or engineered vacuum-fill concept | Vacuum performance, supports, nozzles, monitoring and maintenance |
| LH₂ transfer piping | Low heat leak during transfer and standby | Vacuum-jacketed piping with MLI and engineered supports | Field joints, couplings, valves, contraction and leak testing |
| Valves, vents and instruments | Maintain continuity without blocking operation or inspection | Custom removable or permanent cryogenic details | Stem movement, vent paths, access, sealing and reinstatement |
The system directions above are conceptual. Pressure-vessel, process, piping, safety and OEM design responsibilities remain with the authorised parties defined by the project.
From data to field execution
ERATHERM Engineering Workflow
A controlled sequence connects process conditions and equipment interfaces to calculations, drawings, procurement and installation QA/QC.
Design Basis
Operating cases, temperatures, pressures, ambient conditions, duty cycles, owner criteria and package boundaries.
Interface Register
Equipment, piping, supports, nozzles, valves, field joints, instruments and OEM interfaces mapped by service.
Thermal Analysis
Heat-leak, surface-temperature, thickness and thermal-bridge assessment for governing operating scenarios.
System Design
Material architecture, vapour control, MLI or vacuum interfaces, contraction details, cladding and access strategy.
Detail Engineering
Specifications, data sheets, drawings, MTO/BOM, ITP, method statements and installation workpacks.
Field Assurance
Material verification, installation surveillance, hold points, vacuum-interface coordination, punch and close-out.
Documented engineering
Typical Project Deliverables
The package is adapted to concept selection, FEED, EPC detail engineering, OEM coordination, construction or troubleshooting scope.
Technical framework: Project specifications and jurisdictional requirements are confirmed first. Depending on scope, alignment may include ASME B31.12 for hydrogen piping, ISO 22734-1 for water-electrolysis hydrogen generators, NFPA 2, applicable cryogenic equipment standards and owner engineering practices.
- Insulation Design Basis
- Asset & Interface Register
- Heat-Leak / Thickness Calculations
- Thermal-Bridge Assessment
- Material Selection Matrix
- Insulation System Specification
- Typical & Special Detail Drawings
- Vacuum / MLI Interface Notes
- Valve & Field-Joint Details
- BOM / MTO
- Method Statement & ITP
- QA/QC and Close-Out Dossier
Connected capabilities
Related Cryogenic Engineering Services
Cryogenic engineering
Cryogenic Insulation Systems
System design for tanks, vessels, equipment and piping in low-temperature service.
Explore capability → Vacuum insulationMLI & Vacuum Systems
Multilayer insulation architecture, vacuum interfaces and installation engineering.
Explore capability → Large-scale terminalsLNG Terminal Insulation
Related cryogenic experience for storage, transfer and terminal insulation systems.
Explore capability →Frequently asked questions
Green Hydrogen & LH₂ Insulation FAQ
Early definition of temperatures, operating modes, package limits and performance criteria prevents gaps between process, mechanical, OEM and insulation scopes.
Why is LH₂ insulation different from conventional cold insulation?
Liquid hydrogen operates near 20 K. At this temperature, radiation, structural heat bridges, vacuum quality, material contraction and very small discontinuities can dominate total heat ingress. The design therefore requires an integrated cryogenic system approach.
Which insulation system is used for liquid-hydrogen storage?
Large and small systems may use different engineered concepts. High-vacuum spaces with multilayer insulation or selected vacuum-fill systems are common directions, but the final architecture depends on vessel design, size, pressure, performance target, operating profile and OEM responsibility.
Can ERATHERM calculate heat leak and insulation thickness?
Yes. ERATHERM can develop project-specific heat-transfer and thickness calculations, including thermal-bridge assessment where geometry and input data are available. Acceptance criteria and the governing design cases are agreed with the client.
Do vacuum-jacketed pipes still require detailed insulation engineering?
Yes. Field joints, supports, valves, instruments, couplings, terminations and penetrations can control performance. Vacuum and MLI quality must also be protected through fabrication, transport, installation, testing and commissioning.
What information is needed to start an engineering review?
Process and utility line lists, operating and design temperatures, pressures, equipment data, P&IDs, plot plans, piping drawings, support philosophy, ambient conditions, operating cycles, heat-leak or boil-off criteria and applicable owner specifications are the preferred starting inputs.
Can ERATHERM support FEED, EPC and construction stages?
Yes. The scope can range from concept comparison and FEED calculations to detailed drawings, specifications, MTO/BOM, installation workpacks, field QA/QC and close-out documentation.
Define the thermal boundary early
Discuss Your Green Hydrogen or LH₂ Insulation Scope
Share the process temperatures, equipment list, piping data, performance targets and project phase. ERATHERM can define the insulation design basis, interface register and engineering deliverables required for the next decision.