Hydrogen Fuel-Cell Generators Power the Recycling of Polyester in Northamptonshire.

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In Northamptonshire, UK, hydrogen power takes the leading role in this groundbreaking initiative that does not only curb textile waste but also supports net-sero goals at the national level. Known as Project Re:claim, this initiative involves the Salvation Army Trading Company Ltd (SATCoL) partnering with Project Plan B to pioneer a commercial-scale polyester recycling plant based in Kettering. The plant is designed to turn textile waste into new materials for the fashion industry. Due to substantial delays in securing a traditional grid connection, hydrogen has emerged as the alternative choice for Project Re:claim to power its operations in a sustainable, zero-emission fashion - showing how green hydrogen can support the U.K.’s sustainability ambitions.

The importance of this project cannot be overemphasised because of the huge volumes of textile waste already generated in the UK. 300,000 tonnes of old clothing and household textile wastes are disposed of each year in the UK. Previously considered non-recyclable and consigned to the landfill are some major textiles, such as polyester. Where he says: 'In the UK alone, 300,000 tonnes of textile items are discarded into household waste, including polyester. Up until now, polyester that had no useful life left would have been disposed of.' In a bold move, Project Re:claim has pioneered the adaptation of bottle-recycling technology to break down polyester textiles back into granules, which can then be spun into new yarn for new garments again.

The plant has set ambitious recycling targets: 2,500 tonnes of polyester waste recycled in the first year, and double that in the second year. The only setback was the power: how to get enough power to support this huge intensity of operations sustainably. Grid connection delays, forecast to be between 12-18 months, threatened to stall the project’s momentum and eco ethos. Cue GeoPura, the pioneers in green hydrogen solutions, with its hydrogen-powered generators— or Hydrogen Power Units (HPUs), in short— to provide the off-grid power that is needed to keep Project Re:claim moving forward as though nothing had happened.

Incorporating HPU technology, GeoPura leverages green hydrogen for zero-emission electricity. The technology involves a Proton Exchange Membrane (PEM) fuel cell. Every HPU comes wrapped in a 20-foot shipping container, compactly designed with 250 kW of delivered power output, having 250 kWh battery storage. This process only produces water, which makes it an appropriate power solution for industries prioritising sustainability. In the words of GeoPura CEO Andrew Cunningham, "By harnessing green hydrogen, our HPU technology provides zero-emission electricity and therefore is a perfect solution for projects such as Re:claim, where traditional grid connections of sufficient size are not immediately available."

This collaboration underlines the role that hydrogen can play in meeting net-zero targets, something of paramount importance to the UK in its battle against climate change. A shift by industry away from the use of fossil fuels is achievable, with reliable, versatile, and emission-free power coming from hydrogen then displacing diesel in off-grid applications. The Project is about much more than just providing power to run the plant but rather to set a sustainable benchmark for recycling initiatives in the future.

But hydrogen’s ability to transform the way energy is used in the UK goes much further than just textile recycling. Already operational in defence, electric vehicle charging, and construction sectors, HPUs manufactured by GeoPura are setting the benchmark for the widespread use of these technologies. Large-scale deployment plans, with Siemens Energy spearheading production, are set to see more than 3,600 deployed by 2023. This will blow more than ten million tonnes of CO₂ emissions off the map of Britain’s carbon footprint and drive the country’s changeover to sources of renewable energy.

The benefits of hydrogen to energy resilience and sustainability are apparent. Unlike fossil fuels, hydrogen can be made with zero-carbon energy, and therefore its entire lifecycle from production to use can technically be near-zero carbon. This fact is important for cases in which grid power is not available or is not reliable, which is true for Project Re:claim. Hydrogen can also open up those remote and industrial sites needing their diesel generators for which it is difficult to otherwise ensure low greenhouse gas emissions.

Tim Cross perceives that the success attained by Project Re:claim can set very strong precedent other industries: “GeoPura’s hydrogen power solutions were critical in surmounting this challenge, making the plant capable of working efficiently without the support of any fossil fuels. Not only does this fit into our wish for creating a circular economy for textiles, but it also sets a precedent for recycling initiatives in the future.”

Project Re:claim showcases how renewable energy can effortlessly supply such heavy industrial applications and help the UK work toward its net-zero goals. With attention to initiatives like hydrogen, it should not only prove out the practicability of alternative sources but also underpin much greener industrial practices for the entire country.

At a time when environmental accountability is, with increasing pace, becoming more than just a trend, the co-operation between Project Re:claim and GeoPura shows that sustainable innovation can be achieved. As proven by the success of this collaboration, hydrogen will be at the heart of the solution that helps the country achieve its climate ambitions, allowing for a bright, green, and more robust energy future.

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