The T2X project in Miajadas, Extremadura, has marked a milestone by injecting renewable natural gas directly into the fossil-free distribution grid. This green gas is produced by combining 100% renewable hydrogen with biogenic CO₂ from a bioethanol plant, using the Sabatier reaction. To optimize this process, a digital twin virtually replicates every flow of hydrogen, CO₂, and synthetic methane, enabling simulation of production scenarios, efficiency, and predictive maintenance.
Architecture of the digital twin for the Sabatier reaction 🏗️
The digital twin of the T2X plant is structured in three layers: IoT sensors, physical model, and 3D visualization. Sensors measure in real time the flow of electrolytic hydrogen (9 MW capacity), biogenic carbon dioxide, and the temperature of the catalytic reactor. The physical layer simulates the stoichiometry of the Sabatier reaction (CO₂ + 4H₂ -> CH₄ + 2H₂O), calculating yields and thermal emissions. The 3D visualization shows the pipeline infrastructure, alerting about deviations in injection pressure. This model allows predicting the production of 6,390 tons of renewable hydrogen in its first decade, adjusting solar energy input according to agreements with Axpo Iberia.
Impact on industrial decarbonization 🌍
By digitally modeling the T2X process, it facilitates the decarbonization of sectors that are difficult to electrify, such as steelmaking, ceramics, and maritime transport. The digital twin allows simulating energy efficiency scenarios, reducing operational costs and maximizing the fixed premium of 0.62 euros per kilogram of certified hydrogen for a decade. Extremadura, with its solar radiation, becomes a virtual laboratory to replicate this technology in other European regions, transforming the gas grid into an intelligent and sustainable system.
What technical and modeling challenges were faced when creating the digital twin of the T2X plant to ensure accuracy in simulating the first European renewable gas injected into the distribution grid?
(PS: My digital twin is right now in a meeting, while I'm here modeling. So technically, I'm in two places at once.)