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Article

Design and Layout Planning of a Green Hydrogen Production Facility

by
Caroline Rodrigues Vaz
1,
Eduardo Battisti Leite
1,
Mauricio Uriona Maldonado
1,
Milton M. Herrera
2 and
Sebastian Zapata
3,*
1
Department of Industrial and Systems Engineering, Federal University of Santa Catarina, Florianópolis 88040-900, Brazil
2
Centre for Research in Economic Sciences, Universidad Militar Nueva Granada, Bogotá 110111, Cundinamarca, Colombia
3
Escuela de Ingeniería y Ciencias Básicas, Universidad EIA, Envigado 055420, Antioquia, Colombia
*
Author to whom correspondence should be addressed.
Sustainability 2025, 17(10), 4498; https://doi.org/10.3390/su17104498
Submission received: 17 March 2025 / Revised: 30 April 2025 / Accepted: 12 May 2025 / Published: 15 May 2025
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Abstract

:
In response to the greenhouse gas (GHG) reduction targets set by the Paris Agreement, green hydrogen has become a key solution for global decarbonisation. However, research on the design of green hydrogen production facilities remains limited, particularly in Brazil. This study bridges this gap by developing a comprehensive design for a green hydrogen production plant powered by an 81 MW photovoltaic (PV) system in Ceará, Brazil. The facility layout, equipment sizing, and resource requirements were determined using the Systematic Layout Planning (SLP) method, based on the available energy for daily hydrogen production. The design also integrates safety regulations, including local standards in Ceará, as well as raw material needs and production capacity. This study delivers a detailed facility layout, specifying equipment placement and capacity based on the PV plant’s output while ensuring compliance with safety protocols. This research contributes to the green hydrogen literature by providing a structured methodology for facility design, serving as a reference for future projects, and fostering the advancement of green hydrogen technology, particularly in developing countries.

1. Introduction

The rise in greenhouse gas (GHG) concentrations since pre-industrial times has led to global warming, polar ice cap melting, and rising sea levels [1,2,3]. In response, the Kyoto Protocol, the first international treaty to regulate GHG emissions, was signed in 1997 during the 3rd Conference of the Parties of the United Nations Framework Convention on Climate Change, held in Kyoto, Japan. Under this agreement, industrialised nations committed to reducing their GHG emissions by an average of 5.2% below 1990 levels between 2008 and 2012 [4].
Continuing efforts to combat climate change, 194 countries later ratified the Paris Agreement at COP-21 in France in 2015 [5]. This accord set more ambitious GHG reduction targets, aiming to limit the global temperature rise to below 2 °C—ideally 1.5 °C—compared to pre-industrial levels by 2100.
GHG reduction targets encourage the development of new technologies and investment in clean energy sources [6]. In this context, renewable hydrogen is identified by the European Commission as a key player in achieving net-zero carbon emissions by 2050 [7]. This element has attracted the attention of studies and investments from large industrial companies [8]. However, the high production cost of renewable hydrogen is still a challenge [9,10], which means that the most used method today still involves the release of greenhouse gases.
Despite cost challenges, hydrogen gas is used in various industrial sectors, including fertilisers, petroleum, steel, food, electronics, and energy generation. In the short term, it also holds significant potential for reducing GHG emissions through combustion for electricity generation or fuel cells, as it does not release carbon dioxide like fossil fuels [11]. Additionally, hydrogen can serve as an exporter of renewable energy resources. When produced from clean energy sources, it can be stored and transported, helping to overcome seasonal energy fluctuations [12].
The production of green hydrogen gas (GH2) depends on several factors that influence a country’s competitiveness. These include the availability of renewable energy and water resources, the cost-effectiveness of production, infrastructure and energy demand, space for production, and the social and political framework [13]. Some studies highlight that the viability of green hydrogen depends on technological advancements, cost reductions throughout the value chain, and strong public policy support [14,15,16]. Sanchez-Squella [14] conducted a techno-economic assessment of a green hydrogen complex in Chile, considering its geographical location, solar resources, and company layout. Similarly, Hosseini and Firoozabadi [17] propose and evaluate an innovative hybrid wind-solar layout for green hydrogen production. Their study optimises the design using evolutionary programming and assesses its performance in terms of energy, economics, and environmental impact across different regions of Iran. Mazza et al. [18] present a feasibility study estimating green hydrogen production potential through electrolysis in Tunisia. Their analysis compares various plant layouts, adjusting the size and type of renewable electricity generators and electrolysers to determine optimal configurations. However, there is insufficient evidence on the design and layout planning of green hydrogen production facilities in Latin American countries.
In this scenario, Brazil stands out for its predominantly renewable energy matrix. However, despite its potential as a GH2 producer, several challenges remain, including the high cost of electrolysers and storage processes, the need for adequate electrical infrastructure, regulatory frameworks and incentives, the availability of renewable energy, and water supply logistics. Additionally, the logistics of production, storage, and distribution of the final product pose significant hurdles [11]. The high cost of electrolysers makes green hydrogen two to three times more expensive than hydrogen produced from non-renewable sources [19]. Another crucial factor is the distribution method of GH2, which can follow two main alternatives: centralised production plants, enabling mass production and distribution via pipelines or cylinders, or decentralised plants serving regional markets using hydrogen cylinders [20].
The Northeast region of Brazil, particularly the state of Ceará, has emerged as a hub for the development of green hydrogen (GH2) industries. This is due to several factors, including the region’s abundant renewable energy resources, such as solar and wind power, which are essential for the production of GH2 through electrolysis. Additionally, the region’s strategic location and existing infrastructure make it an attractive destination for investment in GH2 production and export. The Brazilian government has also expressed strong support for the development of the GH2 industry in the Northeast, recognising its potential to contribute to the country’s energy transition and economic growth [21].
Given this context and the existing gap in studies on the sizing and planning of green hydrogen plants, this work addresses the following question: How can a layout for a green hydrogen plant be designed using a photovoltaic energy source for the state of Ceará?
To address this gap, this paper proposes the layout of a green hydrogen plant powered by photovoltaic energy, using the Systematic Layout Planning (SLP) method. It is acknowledged that the overall operational efficiency and economic feasibility of green hydrogen production plants are critically influenced by dynamic factors, notably the inherent variability of renewable energy inputs, such as seasonal fluctuations in solar PV generation and prevailing weather patterns. However, the specific objective of the research presented herein is distinct: to isolate and address the technical challenges and optimisation strategies primarily associated with the physical layout and design of the production facility. This study, therefore, concentrates on spatial considerations, including equipment placement, required safety distances, process flow integration, and land use efficiency within the plant boundaries. Consequently, variables related to the dynamic nature of energy inputs and other real-time operational aspects were intentionally excluded from the scope of this analysis. This focused approach allows for a detailed investigation of the spatial design constraints inherent in developing an efficient facility layout, treating this as a foundational challenge distinct from, although interconnected with, the broader operational dynamics of the plant.
This paper is structured as follows: Section 2 outlines the three-stage research methodology. Section 3 presents the results related to the plant’s design. Section 4 examines this study’s contributions to the growing body of knowledge on green hydrogen, with a particular focus on the Brazilian context and the design of a photovoltaic-powered facility. Finally, Section 5 presents the conclusions.

2. Methodology

This study adopts a three-stage methodology to design a green hydrogen production facility powered by photovoltaic energy with the following stages: (1) a technical visit for data collection, (2) layout planning using the Systematic Layout Planning (SLP) method, and (3) a risk and safety analysis.

2.1. Technical Visit

A technical visit was conducted to a pilot green hydrogen plant in Florianópolis, Brazil. Data regarding equipment specifications, process flows, and safety measures were collected. The plant uses a 25-kW photovoltaic system, battery storage, and an anion exchange membrane electrolyser. These insights supported the definition of the layout requirements and validation of the SLP approach [22,23].

2.2. Layout Planning

In this study, the Systematic Layout Planning (SLP) method was employed, which consists of four phases: location selection, general arrangement, detailed arrangement, and implementation. Tools such as process charts, relationship and inter-relationship diagrams, and space inter-relationship diagrams were used to analyse material flows and spatial dependencies.
To calculate the spatial requirements, we applied the Guerchet method, which determines the total required area (ST) for each equipment based on Equation (1), where Sp is the projected area, So is the operating area, and Sc is circulation space. Adjacency requirements were validated using the Adjacency Ratio (AR), with an acceptance threshold of 85%.
S T = S p + S o + S c

Rationale for Equipment Sizing and Spatial Allocation

Production capacity needs, equipment specifications, and compliance with Brazilian safety laws (NR-20, NR-23, and NR-24) helped to define the sizing and spatial allocation of every sector in the facility plan. The design enables a goal daily hydrogen output of 108,000 Nm3. Including operating clearance and circulation space, the electrolysis sector comprises eight Longi LHy-A1500 electrolysers, each measuring 8 m × 35 m, therefore generating a total production area of 2240 m2. Designed to hold 450 Amp Nova commercial storage units (150 kW each), arranged in nine banks of 50 units, totalling 4392 m2, the battery room was intended to store excess photovoltaic energy. Requiring 1930 m2 with clearances and separations set in line with NR-20, hydrogen storage consists of 23 GD5-600/15-350 compressors and 7200 high-pressure gas cylinders. Based on a demand of 87,382.8 L daily, one NEA-OR 9000 reverse osmosis system (10,000 L/h) and three storage tanks covering 101 m2 define the water treatment sector. Furthermore, contained in line with NR-24 were support areas, including reception, cafeteria, bathrooms, and offices, which totalled 343 m2, including circulation space. The Guerchet approach, which totals the projected area (Sp), operational area (So), and circulation space (Sc), was used to determine all spatial allocations. Table 1 provides comprehensive results. A 100% Adjacency Ratio (AR) validation of the configuration confirmed ideal spatial efficiency and functional integration.

2.3. Safety Analysis

A thorough risk mapping procedure was carried out to find, classify, and reduce possible dangers connected to green hydrogen generation, thereby guaranteeing a safe working environment all around the facility. This map conforms with industry best standards for occupational health and safety and functions as a visual diagnostic tool. Type (chemical, physical, biological, ergonomic, mechanical) and severity helped to classify risks so that important management strategies could be prioritised in many different industries. Supported by a thorough preliminary risk analysis (PRA), the assessment tightly followed Brazilian regulatory standards—NR-20 (handling flammable and combustible materials) [24], NR-23 (fire protection), and NR-24 (sanitary and comfort conditions in the workplace), and systematically evaluated the likelihood and consequences of each hazard.
The quantification of the fire load—which, in line with NT08 (CBMCE) and ABNT safety classifications was classed as Medium Risk, due to the presence of hydrogen gas held under high pressure—was a primary focus of the investigation. This classification determined the kind, amount, and strategic positioning of fire extinguishers in line with NT21, therefore assuring suitable coverage for Class A, B, and C fires (solid materials, flammable gases/liquids, and electrical threats, respectively). Selected and placed throughout important regions, especially around hydrogen storage, electrical systems, and manufacturing zones, portable ABC powder extinguishers with a capacity of 2-A:20-B:C were used.
Moreover, as advised by NT05, the layout design included emergency exit planning, which included evacuation capacity, accessibility of escape routes, and maximum allowed travel distances. Following NBR 13434-1 and CBMCE guidelines helped to ascertain exit door specifications, meeting point locations, and signs, thereby guaranteeing appropriate visual direction for quick evacuation during an emergency. Considering the layout, fire risk profile, and existence of high-pressure hydrogen systems at the facility in Ceará, all safety procedures and protective measures were tailored to the operational setting of the construction. This combined strategy of risk management improves worker safety and regulatory compliance as well as the facility’s general resilience against hazardous incidents.

2.4. Software

This study used Autodesk Factory Design Utilities 2024, which includes AutoCAD 2024, Inventor 2024, and Navisworks 2024. This software allows the creation of 2D and 3D layouts, the integration of construction and equipment information, and the simulation of the production process. AutoCAD was used to develop the 2D model of the layout, including the dimensions and arrangement of the sectors. Inventor allowed the creation of the 3D model, with the insertion of equipment and the simulation of material flow. Navisworks was used for the visualisation and analysis of the 3D model and the creation of images and animations. This study leveraged the Autodesk Factory Design Utilities suite, comprising AutoCAD, Inventor, and Navisworks, to comprehensively design and simulate the proposed factory layout. This software suite offers a robust platform for creating detailed 2D and 3D layouts, integrating crucial construction and equipment data, and dynamically simulating the entire production process.

3. Results

3.1. The Green Hydrogen Value Chain

The design of the green hydrogen production process was based on a study of an existing green hydrogen plant in Florianópolis, Brazil. This study included choosing a solar power plant as the energy supply and sizing the necessary equipment. The resulting production chain consists of solar energy production, battery backup, water purification, electrolysis, hydrogen compression, and storage in tanks. The green hydrogen chain’s workflow is shown in Figure 1.
The analysis is centred around the operation of a plant dedicated to the production and storage of hydrogen gas. Ammonia production is not included in this study. For the purpose of this calculation, the plant will operate on an 8-h daily shift dedicated to hydrogen production.
During the generation of electricity by the photovoltaic plant, the energy is directed to rectifiers, which stabilise the power before being injected into the electrolysers. If the energy generated during the day exceeds the demand of the electrolysers, the excess is stored in the battery system for later use. The plant is connected to the hydraulic system to ensure a continuous supply of water for the process which, before being used in electrolysis, goes through filtering and treatment stages.
After production, the oxygen gas is released into the atmosphere, while the hydrogen is transported through pipelines to the storage sector, where it is compressed by compressors and stored under a pressure of 300 Bar in compressed cylinders. At the end of the day, tanker trucks are positioned in the expedition area and are supplied with the hydrogen gas produced during the shift, to then carry out the delivery to the destination.
The design of the new plant was based on the existing photovoltaic plant, Steelcons Sol do Futuro (Figure 2). This photovoltaic complex has a total capacity of 81 MW, across three photovoltaic plants installed on a 203.56-hectare private property. The area occupied by the plants is 151.19 hectares. Equipment for the new plant, including electrolysers, batteries, compressors, and storage cylinders, was sized based on the average daily generation of the existing photovoltaic plant.
The Longi LHy-A1500 electrolyser was selected for its high production capacity, with eight units being allocated for the plant. Amp Nova Commercial Solar Battery Storage units were chosen to store excess energy, with a total of 450 units allocated [25].
For hydrogen compression, the G5 Series Diaphragm Compressor Features, model GD5-600/15-350, was selected, with 23 units allocated. Hydrogen storage will be achieved using 7200 high-pressure cylinders [26].
Equipment sizing considered the average daily hydrogen production of 108,000 Nm3, a water demand of 87,382.8 L, and the requirement for water treatment. The Puertollano Plant, Europe’s largest green hydrogen production facility for industrial use, served as a reference for the design.
The Puertollano Plant comprises a 100 MW solar photovoltaic park, a 20 MWh lithium-ion battery storage system, and a 20 MW electrolysis-based hydrogen production system. The higher Global Horizontal Irradiance in the Brazilian Northeast compared to Spain justified the selection of a photovoltaic plant with a slightly lower capacity than the Puertollano Plant [27].
Sustainability 17 04498 g002
Figure 2. Overview of the Steelcons Sol do Futuro Photovoltaic Plant, serving as the basis for the new green hydrogen production facility design. Source: Atlas Renewable Energy [28].
Figure 2. Overview of the Steelcons Sol do Futuro Photovoltaic Plant, serving as the basis for the new green hydrogen production facility design. Source: Atlas Renewable Energy [28].
Sustainability 17 04498 g002
The design of the plant is based on the installed capacity of the existing Steelcons Sol do Futuro PV plant in Ceará. This complex has a total capacity of 81 MW and occupies an area of 151.19 hectares. The installation uses 94,048 photovoltaic modules in each plant, GCL brand, model GCL-P6/72 320 W, multi-crystalline, with a power of 320 Wp.
Based on the plant’s generation history, the monthly average of generated energy was calculated, which will be used by the hydrogen plant, being 17.07 MW or 12,289.08 MWh per month. The average daily generation of the plant corresponds to 0.57 MW or 409.64 MWh [29].
Regarding the sizing of the battery bank, as well as the electrolysers, given the limitations found in the academic literature on the subject, it was decided to carry out a more comprehensive search on the batteries available in the current market, with the objective of identifying those most suitable for storing energy from photovoltaic generation, prioritising those with the highest storage capacity and that meet the requirements of the proposed production process, having their dimensions and specifications available. Thus, the chosen equipment was the Amp Nova Commercial Solar Battery Storage [30].
With the choice of batteries, so that they can provide the necessary energy to the electrolyser, the power provided must be equivalent to the operating power of the equipment. Considering that the operating power of the electrolyser is 7.5 MW and that of each battery is 150 kW, it is necessary to connect 50 batteries in parallel to add their powers and reach the desired value. In this way, the batteries must be organised in banks of 50 units connected in parallel to provide the power of 7.5 MW to the electrolysers.
After determining the number of batteries required to operate in parallel and meet the power demands of the equipment, the next step is to calculate the total number of battery banks needed for the project. The Puertollano Plant, for reference, utilises a 20 MWh battery system paired with a 20 MW hydrogen production system. In contrast, the plant designed in this study employs eight electrolysers, each with a power rating of 7.5 kW, resulting in a combined power output of 60 kW. This represents three times the hydrogen production capacity of the Puertollano Plant. Consequently, a battery system with a proportionally larger storage capacity was designed to support this increased production.
We assume a storage capacity of 90 MWh. The system includes nine banks of 50 batteries each, totalling 450 units. These batteries occupy an area of 1089 m2 and provide a storage capacity equivalent to 20% of the plant’s average daily power generation.
Regarding the storage of compressed hydrogen gas, 1 Nm3 is equivalent to 1000 L [31]. Therefore, the average daily production of 108,000 Nm3 equals 108,000,000 L per day.
For the electrolysis process, high water purity is crucial, necessitating treatment and filtering [32]. Due to limited information in the academic literature [33], a comprehensive market survey was conducted to identify suitable water purifiers. The aim was to select equipment that met the proposed production process requirements and for which dimensions and specifications were available.
Given a daily water demand of 87,382.8 L, the treatment system must purify enough water for the following day’s consumption to prevent any interruptions in hydrogen production. Consequently, the NEA-OR 9000 reverse osmosis system was selected. This system has a treatment capacity of 10,000 L per hour and dimensions of 2500 × 1100 mm, occupying an area of 2.75 m2.
Table 1 provides a detailed breakdown of the essential equipment and their specifications for each stage of the production process, directly informing facility planning and layout. The plant designed for green hydrogen (H2V) production, with a capacity of 108,000 m3 of H2V, requires 409.64 MWh of electricity and 87,383 L of pure water. To support this production, for the battery room, the dimensions of each of the 450 batteries necessitate a total area of 1089 square metres. The water treatment stage requires 2.75 square metres for a single water purifier unit. Three tanks, each measuring 3.2 m in width and length, are allocated for storing water or other process materials, although their total volume or area requirement is not explicitly detailed. The core production area, housing eight electrolyser units with specified dimensions, demands a total of 2240 square metres. The storage area accommodates 23 compressor units for gas storage and compression, requiring 262.2 square metres. A significant quantity of 7200 cylinders is utilised for gas storage and transportation; while individual dimensions are provided, the total area for their storage is not explicitly stated. Finally, a dedicated maintenance area, occupying 2.65 square metres, is designated for storing 50 spare cylinders. This comprehensive data on the equipment specifications and spatial needs for each stage is crucial for effective facility planning, equipment procurement, and overall process optimisation, enabling a clear understanding of the resources and space allocation required for the green hydrogen production facility.
In Figure 3 we provide a detailed mapping of the key activities involved in green hydrogen production.

3.2. Layout Design for the Green Hydrogen Plant

The layout design of the green hydrogen production facility followed the Systematic Layout Planning (SLP) method, which integrates process flow, spatial relationships, and safety considerations. Key sectors were defined based on the production workflow: photovoltaic plant, water treatment and storage, battery room, hydrogen production, hydrogen storage, expedition, and maintenance.
A relationship diagram was then created to illustrate the necessary proximity between these sectors, as presented in Table 2.
Relationships marked with code 1 indicate a high volume of material or product movement. This signifies that, during the production process, one area directly follows another sequentially, resulting in intense material movement due to high demand in adjacent sectors and, consequently, in a high-intensity operational flow. Code 2 refers to sectors with low or circumstantial movement of materials and products. For example, the energy from the batteries will be used by the production sector only when the energy supply from the plant to the electrolysers is insufficient to meet the full production capacity.
Code 3 identifies sectors that have no movement between them and therefore, do not need proximity. Finally, code 4 represents a reason involving safety standards that justify the proximity or distance between two sectors or the risk of accident, such as, for example, NR 20—Safety and Health at Work with Flammable and Combustible Materials. Figure 4 presents the relationship diagram of the different sectors of the projected factory.
Several key relationships are highlighted in Figure 5. The photovoltaic plant and battery room are linked with an “E” (code 2), reflecting their conditional proximity. The plant only charges the batteries when energy generation exceeds electrolyser demand. The same conditional relationship exists between the battery room and hydrogen production, as previously explained. The maintenance/neutralisation sector is marked with an “I” (code 2) in relation to both hydrogen storage and hydrogen production. This sector injects argon into the hydrogen pipelines during maintenance to neutralise any residual H2, a safety precaution mandated by NR20, which addresses flammable vapour and gas emissions during transfer and filling operations.
Sectors marked with “A” (code 1) represent areas with high material/product flow, and thus require proximity. These include the connections between the photovoltaic plant and the water storage and treatment (1 and 4), the water storage and treatment and hydrogen production (2 and 4), and the hydrogen storage and dispatch (5 and 6) sectors.
Finally, “X” (code 4) denotes sectors that must be spatially separated for safety reasons. The battery room and water storage must be distant to prevent short circuits in case of water tank leaks. The dispatch area is kept separate from the photovoltaic plant to avoid accidents involving the generation system and the highly flammable hydrogen tank trucks. Critically, NR20 mandates a separation between hydrogen storage and both the battery room and hydrogen production areas. This standard requires gas storage facilities to be well-ventilated, distant from heat, sparks, and flames, and physically separated from production areas by a wall.
These inter-departmental relationships were translated into a spatial layout, shown in Figure 5.
Based on the connections between the sectors, obtained through the inter-relationship diagram developed in the previous item (see Figure 5), the space inter-relationship diagram was developed, which shows the interconnection between the sectors. Figure 6 presents a preliminary layout of the factory, without yet considering the specific areas needed for each sector.
By means of equipment size, required operational clearances, and circulation zones, Table 3 demonstrates the spatial needs of the facility, thereby getting a total estimated facility area of 10,886 m2 (excluding the photovoltaic field). Combining the earlier space inter-relationship and block diagrams into one coherent scaled layout, the full layout logic is now focused into a single integrated picture (Figure 7). This graphic quite successfully shows sector adjacencies, spatial equipment distribution, common-use spaces, and process flows. The efficiency and viability of this spatial arrangement were methodically demonstrated using the Adjacency Ratio (AR) computation, which achieved 100%, significantly over the allowed threshold of 85%.
Strong spatial and operational integration assured by this integrated approach ensures tight matching of equipment layout with legal safety regulations, production targets, and operational maintenance issues. Important safety criteria, such as the necessary isolation between hydrogen storage and power components (i.e., the battery room), ensure significant compliance with NR-20 and NR-23, thereby considerably enhancing both functional efficiency and operational safety.
The space inter-relationship diagram (block diagram), illustrated in Figure 8, was formulated after establishing the dimensions of each sector. This diagram provides a comprehensive overview of the factory layout, incorporating the area of each sector. It is evident that the photovoltaic plant’s area (1,511,900 m2) vastly overshadows the combined area of the remaining sectors (10,886 m2). Due to this significant size disparity, representing the photovoltaic plant block at its actual scale would hinder the clear visualisation and arrangement of the other sectors.
To enhance spatial efficiency and adhere to safety regulations, the maintenance and storage sectors were amalgamated, as both employ gas cylinders, and the maintenance area covers a relatively small footprint. Furthermore, communal areas, including a reception (86 m2), cafeteria (66 m2), accessible restrooms (47 m2), and two offices (28 m2), were consolidated into a single block designated as “Reception” in Figure 8. The areas mandated by NR 24: Sanitary and Comfort Conditions in Workplaces encompass a total of 342 m2, inclusive of circulation space.
The dimensions data illustrated in Figure 7 and Table 3 were obtained from the Guerchet approach, which includes each equipment’s footprint (Sp), operational space (So), and circulation requirements (Sc). The design was meticulously calibrated to facilitate a production target of 108,000 Nm3/day of hydrogen. The production area (3616 m2) contains 8 electrolysers measuring 8 m × 35 m, whereas the battery room (4392 m2) houses 450 commercial storage units, organised in parallel banks to satisfy the plant’s power requirements. The sizing parameters were evaluated against the Puertollano Plant in Spain and proportionately adjusted according to the available solar generation and storage needs. This context offers a definitive justification for the spatial arrangement and enhances the technical consistency of the proposed facility design.
Figure 8 illustrates the three-dimensional configuration of the facility, offering a spatial representation of the plant’s sectors, their respective dimensions, and their interrelations. This representation enhances the block and process diagrams by providing a more lucid comprehension of the physical layout, equipment dimensions, and circulation areas. The 3D model assists in verifying safety distances, especially between the hydrogen storage area and the electrolysis and battery sectors, assuring adherence to NR-20 and NR-23 regulations.

3.3. Designing Workplace Safety Measures

The goal of workplace safety is to safeguard the well-being and health of all building occupants and workers. The first step in establishing a safe working environment is to pinpoint potential hazards linked to the facility’s activities and environments. These hazards can stem from various sources and are categorised into five groups: physical, chemical, biological, ergonomic, and mechanical. To aid in identification, a risk map was created, which visually depicts the types and levels of risk present in each area. This map, along with an explanatory legend, is shown in Figure 9.
The preliminary risk analysis (PRA), based on the risk map in Figure 10, is detailed in Table 4. This analysis was essential to outline the main identified risks according to their criticality (frequency and severity). The table below provides definitions for each level of Frequency, Severity, and Risk.
Table 4 shows that risks associated with hydrogen gas and high-power equipment have the highest risk index and require the most attention. These risks should be prioritised due to the potential severity of injuries and the impact they could have on overall factory safety. Noise and ergonomic risks are considered lower priority as they are less severe and more easily addressed.
To comply with safety standards, the factory design process included a review to identify areas requiring safety and fire prevention signage. This review was based on NR 23, which regulates fire protection in workplaces.
The Military Fire Department of Ceará (CBMCE) utilises Current Technical Standards (NTs) to establish fire safety protocols. The initial step involves assessing the property’s risk level, considering factors such as its activity, size, and fire load. This assessment then determines the necessary security measures. As per NT08—Fire Load in Buildings and Risk Areas (CBMCE, 2008b), the specific fire load of the hydrogen storage facility is 656 MJ/m2. This calculation considers the calorific value of hydrogen (143 MJ/kg), daily hydrogen production (9709 kg), and the area of the hydrogen storage sector (2010 m2). Based on NT01 (CBMCE, 2024a), this specific fire load classifies the property as a Medium Risk. Due to the storage of approximately 9709 kilos of highly flammable hydrogen gas, the designed factory falls under Group M, division M-2. This classification encompasses buildings used for the production, handling, storage, and distribution of flammable or combustible liquids or gases.
The Military Fire Department of Ceará’s NT21 regulation mandates that the extinguisher prevention system must include portable units with a minimum capacity of 2-A:20-B: C. These ABC powder extinguishers, with 2 kg and a discharge time between 8 and 12 s, were chosen due to the presence of flammable gases, electrical equipment, and furniture in the factory. As per the NT21 extinguisher standard, the ABC class extinguisher is suitable for combating fires involving solid materials (A), flammable liquids and gases (B), and electrical risks (C) from equipment present in the sectors.
The design and specification of exit doors is a crucial aspect of emergency exit planning, which should encompass the entire factory. For Group M installations without automatic fire detection, the maximum travel distance to an exit is 40 m, as per NT05 [34].
Finally, another essential requirement for factory safety management is Location Abandonment Signalling (SAL), which indicates the escape route established in the emergency plan. In the building in question, sets of signs must be installed that indicate the exit and safety equipment. NBR 13434-1 specifies the main signs for buildings of this type, including their meanings and appropriate locations for installation [35]. In addition, it is necessary to establish a meeting area outside the facility in case of an emergency. Figure 10 shows the escape route for the designed factory.

4. Discussion

This study contributes to the growing body of knowledge on green hydrogen, particularly within the Brazilian context, specifically focusing on the design of a green hydrogen plant using photovoltaic energy. Most research in this area is concentrated in countries with more advanced technological development in green hydrogen, such as Germany, Japan, China, and the United States [36,37,38,39].
The use of the Systematic Layout Planning (SLP) method for designing the plant layout proved effective in optimising the production flow and, potentially, in minimising operational costs due to the integrated nature of the sectors. Similar results have been found in other studies that used SLP in various industrial contexts, such as automotive battery manufacturing and upholstery production [40,41,42]. Therefore, the application of the SLP method for planning a green hydrogen plant powered by photovoltaic energy is a distinctive aspect of this study, aligning with several research studies on the importance of layout planning for production process efficiency [43,44].
The emphasis on safety, through the development of a risk map/preliminary risk analysis and the implementation of safety measures such as fire extinguishers and emergency exits, is consistent with the recommendations of Figueiredo et al. [45] and Delgadillo [46]. The use of software such as AutoCAD, Inventor, and Navisworks for creating the 3D layout is consistent with the methodology employed by Bohler [47].
The choice of Ceará as the plant location is justified by the high incidence of solar radiation in the region, as pointed out by Esteves et al. [48] and de Souza et al. [49]. The sizing of equipment, such as electrolysers and batteries, considered the average daily hydrogen production and water demand, in line with the research of Hunt et al. [50] and Madsen [51].
The equipment sizing and production capacity of the plant designed in this study are comparable to those of other research in the field of green hydrogen production. The average daily hydrogen production of 108,000 Nm3 is in line with the production capacity of other industrial-scale green hydrogen plants, such as the Puertollano Plant in Spain, which has a production capacity of 20 MW. The water demand of 87,382.8 L per day is also consistent with values found in other studies, such as Madsen’s [51] study on water treatment for green hydrogen generation.
The discussion of the results in relation to other research in the field reinforces the relevance of this study for the development of green hydrogen production in Brazil, as discussed in Costa [52] and Bezerra [53], which highlights Ceará’s potential as a green hydrogen production hub in Brazil due to the high availability of renewable wind and solar resources, infrastructure, and favourable public policies. Costa’s [52] study further analyses the macro-location of green hydrogen plants in Brazil, considering criteria such as the availability of renewable resources, infrastructure, and logistics. Bezerra [53] analyses the potential of green hydrogen as an energy vector for decarbonising the economy, with a focus on Ceará.
Puga and Asencios [11] and Shiva Kumar and Lim [19] explore the challenges and advances in the production, storage, and transportation of green hydrogen. Puga and Asencios [11] discuss the limitations and opportunities of green hydrogen production in Brazil, addressing costs, infrastructure, and logistics. Shiva Kumar and Lim [19] review water electrolysis technologies, including alkaline, AEM, PEM, and SOEC, comparing their efficiencies and costs.
Souza et al. [54] and Ranish et al. [55] focus on green hydrogen production through water electrolysis. Souza et al. [54] propose a green hydrogen production model based on wind farms and small hydropower plants, analysing the technical and economic feasibility of the process. Ranish et al. [55] review water electrolysis technologies, focusing on alkaline, PEM, and high-temperature electrolysis, discussing their operating principles and applications.
Collectively, these studies provide a comprehensive overview of green hydrogen production, from technological and economic aspects to challenges and opportunities. The results found in this study align with the trends observed in these studies, contributing to the advancement of knowledge and the development of the green hydrogen sector in Brazil.

5. Conclusions

This study successfully designed a layout for a green hydrogen production plant in Ceará, Brazil, utilising photovoltaic energy. This was achieved by identifying the necessary production equipment, assessing demand, and determining the plant’s production capacity. The Systematic Layout Planning (SLP) method proved effective in constructing the plant’s layout, optimising the production flow, and minimising operational costs. A detailed analysis of the processes, combined with 3D simulation, facilitated the creation of a safe and efficient work environment that complies with safety regulations and supports large-scale green hydrogen production.
This study contributes to the growth of the green hydrogen sector in Brazil by demonstrating the technical feasibility and future economic viability of producing green hydrogen from renewable sources. This work also serves as a benchmark for developing similar projects, promoting the adoption of green hydrogen technology and a more sustainable energy future.
This study, while presenting a practical engineering analysis for the design of a green hydrogen production facility, has some important limitations. Firstly, the geographical focus on the state of Ceará restricts the direct applicability of the results to other regions with different climatic conditions, infrastructure, and regulations. Secondly, the concentration on production from photovoltaic energy and the exclusion of ammonia production limit the scope of the green hydrogen value chain analysis. The reliance on publicly available data and market information for the sizing of some equipment, such as water purifiers, introduces uncertainties in the results. Furthermore, the preliminary safety analysis and the absence of a detailed cost and economic feasibility assessment, as well as a limited analysis of storage and transportation alternatives, indicate areas for future investigations. Therefore, the conclusions of this research should be interpreted considering these restrictions and future studies are necessary for a more complete and accurate understanding of green hydrogen production in Brazil, including the exploration of other renewable energy sources, ammonia production, and more in-depth analyses of safety, costs, and logistics.
Future research should explore alternative hydrogen storage methods, such as liquid or solid-state storage, and pipeline transportation. Evaluating the costs and benefits of each alternative is crucial for making informed decisions about the best approach.
Another recommendation is to develop layouts that include ammonia production, an energy carrier with significant potential for transporting and utilising green hydrogen. Integrating ammonia production into the green hydrogen plant can offer economic and environmental benefits, as well as broaden the range of products generated. Finally, it is recommended to develop green hydrogen plant designs tailored to the specific needs of sectors such as metallurgy and fertiliser production. Customised projects can increase efficiency, reduce waste, and enable the more targeted and strategic use of green hydrogen.

Author Contributions

C.R.V.: conceptualisation, methodology, writing—original draft preparation; E.B.L.: software, validation, data curation, investigation, formal analysis; M.U.M.: conceptualisation, methodology, writing—original draft preparation; M.M.H.: visualisation, validation, writing—review and editing; S.Z.: supervision, project administration, resources, funding acquisition, writing—review and editing. All authors have read and agreed to the published version of the manuscript.

Funding

This research was funded by Minciencias, grant number 71391.

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

The data presented in this study are available on request from the corresponding author.

Conflicts of Interest

The authors declare no conflicts of interest. The funders had no role in the design of this study; in the collection, analysis, or interpretation of data; in the writing of the manuscript; or in the decision to publish the results.

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Sustainability 17 04498 g001
Figure 1. Workflow of the green hydrogen production chain based on a case study of an existing facility in Florianópolis, Brazil. Source: Authors.
Figure 1. Workflow of the green hydrogen production chain based on a case study of an existing facility in Florianópolis, Brazil. Source: Authors.
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Figure 3. Process chart for the plant. Source: Authors.
Figure 3. Process chart for the plant. Source: Authors.
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Figure 4. Relationship diagram of factory sectors with proximity codes based on operational and safety considerations. Source: Authors.
Figure 4. Relationship diagram of factory sectors with proximity codes based on operational and safety considerations. Source: Authors.
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Figure 5. Inter-departmental relationships diagram. Source: Authors.
Figure 5. Inter-departmental relationships diagram. Source: Authors.
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Figure 6. Space inter-relationship diagram for the plant. Source: Authors.
Figure 6. Space inter-relationship diagram for the plant. Source: Authors.
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Figure 7. Final layout in 2D. Source: Authors.
Figure 7. Final layout in 2D. Source: Authors.
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Figure 8. Final layout in 3D. Source: Authors.
Figure 8. Final layout in 3D. Source: Authors.
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Figure 9. Risk map for the plant. Source: Authors.
Figure 9. Risk map for the plant. Source: Authors.
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Figure 10. Emergency escape route and meeting point for the designed green hydrogen production facility. Source: Authors.
Figure 10. Emergency escape route and meeting point for the designed green hydrogen production facility. Source: Authors.
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Table 1. Means of production and equipment.
Table 1. Means of production and equipment.
SectorProductive MeansAmountWidth (m)Length
(m)		Needed
Area
Battery roomBatteries 4502.21.11089
Water treatmentPurifier12.51.12.75
Tanks33.23.230.72
ProductionElectrolyser88352240
StorageCompressor2342.85262.20
Cylinders72000.230.23380.88
MaintenanceCylinders500.230.232.65
Source: Authors.
Table 2. Relationships and proximity reasons.
Table 2. Relationships and proximity reasons.
ColourCodeProximityCodeReason
AAbsolutely necessary1Direct movement of materials/product
EEspecially necessary2Indirect movement of materials/product
IImportant3No movement of material/product
ONot very important4Accident risk/safety standard
UUnimportant
XUndesirable
Source: Authors.
Table 3. Sector sizing based on the plant’s equipment.
Table 3. Sector sizing based on the plant’s equipment.
SectorsEquipmentAmount
(n)		Width
(m)		Length
(m)		Free Edges
(n)		Sp
(m2)		So
(m2)		Sc
(m2)		St by Station (Sp + So + Sc)ST (St × n)
(m2)		Total Area
(m2)
Battery roomBatteries4502.21.142.424.842.59.7643924392
Water treatmentPurifier12.51.142.755.508.258.25101
Tanks33.23.2310.2420.48030.7292.16
H2 productionElectrolyser88354280172045236163616
H2 storageCompressor2342.85411.4022.8034.20786.61930
Cylinders72000.230.2310.050.050.05290.161142.64
MaintenanceCylinders480.230.2310.050.0500.167.628
ExpeditionSupply area8315345573105840840
Total10,886
Source: Authors.
Table 4. Risk classification matrix.
Table 4. Risk classification matrix.
Categories
RiskCauseConsequenceFrequencySeverityRisk
Level		Mitigation Measures
ChemicalPotential leak of hydrogen gas, a highly flammable and reactive elementAsphyxia, explosion, and fireDIV51: Install appropriately sized exhaust fans to quickly remove hazardous gases.
2: Install specific sensors with visual and audible alarms to detect leaks and allow for immediate response.
3: Equip the team with PPE.
4: Train the team in emergency procedures and conduct evacuation and response drills.
PhysicalPhysical risks due to prolonged exposure to machine noiseStress, irritability, hearing lossDII3Use of PPE.
BiologicalLack of hygiene in restrooms and changing roomsPossible infection due to accumulation of bacteria in the environmentsDII3Daily cleaning and ventilation of environments.
ErgonomicRepetitive movements and improper posturesRepetitive strain injuries due to repetitive movements and tingling in lower limbsCII2Take breaks and perform work gymnastics.
MechanicalMechanical risks related to handling and maintenance of machinesInjury of moderate and high severityDIV5Allow handling only by workers qualified for the task, giving their full attention and use of PPE.
Convention:
FrequencyColourSeverityRisk Level
A—Very Unlikely5I—Negligible1—Negligible
B—Unlikely4II—Marginal2—Minor
C—Occasional3III—Critical3—Moderate
D—Likely2IV—Catastrophic4—Serious
E—Frequent1 5—Critical
Source: Authors.
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Rodrigues Vaz, C.; Battisti Leite, E.; Uriona Maldonado, M.; Herrera, M.M.; Zapata, S. Design and Layout Planning of a Green Hydrogen Production Facility. Sustainability 2025, 17, 4498. https://doi.org/10.3390/su17104498

AMA Style

Rodrigues Vaz C, Battisti Leite E, Uriona Maldonado M, Herrera MM, Zapata S. Design and Layout Planning of a Green Hydrogen Production Facility. Sustainability. 2025; 17(10):4498. https://doi.org/10.3390/su17104498

Chicago/Turabian Style

Rodrigues Vaz, Caroline, Eduardo Battisti Leite, Mauricio Uriona Maldonado, Milton M. Herrera, and Sebastian Zapata. 2025. "Design and Layout Planning of a Green Hydrogen Production Facility" Sustainability 17, no. 10: 4498. https://doi.org/10.3390/su17104498

APA Style

Rodrigues Vaz, C., Battisti Leite, E., Uriona Maldonado, M., Herrera, M. M., & Zapata, S. (2025). Design and Layout Planning of a Green Hydrogen Production Facility. Sustainability, 17(10), 4498. https://doi.org/10.3390/su17104498

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