| Client | Element Resources Inc. |
| Project | Lancaster Clean Energy Center Phase 1 FEED |
| Sector | Energy & Chemicals |
| Services | FEL 3 – FEED |
| Location | United States of America |
Objective
To support Element Resources in the development of the Lancaster Clean Energy Center (LCEC) Phase 1, a green hydrogen production facility powered entirely by on-site photovoltaic (PV) solar arrays, by delivering robust Front-End Engineering Design (FEED) to ensure project maturity and readiness for Final Investment Decision (FID).
Project Scope
The LCEC Phase 1 FEED project covered:
- Development of an integrated, off-grid green hydrogen production facility comprising:
- 650 MW ground-mounted PV solar farm.
- 350 MWh Vanadium Flow long-duration energy storage (LDES) system.
- 400 MWe electrolysis plant with hydrogen compression, liquefaction and storage systems.
- Supporting utilities, microgrid control systems and offloading infrastructure.
- Completion of FEED deliverables, including:
- Process design studies for cooling, compression and hydrogen storage.
- Vendor assessments for electrolysers, liquefaction and LDES technologies.
- Detailed engineering across disciplines (process, mechanical, electrical, instrumentation, piping, civil, structural and safety & risk).
- Development of an AACE Class 3 cost estimate and Level 2 execution schedule.
- Alignment of technical definition with regulatory and permitting requirements, stakeholder expectations, and the project’s economic model.
Key Execution Metrics & Outcomes
Key Execution Metrics
- Total Duration: 6 months (5 months technical + 1 month execution readiness)
- Total Number of Deliverables: 233
- Full Time Equivalents (at peak): 19
- Weekly Progress Achieved (at peak): 6-8%
- Client Management: Regular 2 weekly trips to the USA to be co-located with Client
Outcomes
- Decision Quality on electrolyser OEM, early evaluation resulted in a pivot to initially assumed OEM because of inadequate maturity in their techno-commercial offering.
- Liquefaction and compression technologies OEM selection and integration.
- Vanadium Flow LDES technology was confirmed as suitable, with no changes to the existing design or OEM.
Outcomes
- PV solar design optimisation identified potential efficiency gains through a tracker system.
- Detailed integration of main technology providers offering into overall plant design, translated to Material Requisitions and hence scope for EPC integrator.
- Multi-discipline design delivery to support level of accuracy of cost and schedule estimates and EPC tendering.
- Safety design to ALARP and in line with local and international standards.
- Design and safety reviews including: HAZID, HAZOP, SIL, 3D Model & Constructability Review, third party review of safety concept.
- Detailed contracting strategy and execution plan to align stakeholders and streamline detailed engineering, procurement, construction, commissioning and ultimately handover to operations.
io Value Add
io provided crucial contributions to the LCEC Phase 1 FEED project, including:
- Technical Expertise: Conducted thorough vendor assessments, enabling better-informed decisions that enhanced the project’s technology readiness and operational reliability.
- Integrated Engineering: Delivered comprehensive FEED deliverables, ensuring a robust Basis of Design and integration across technology packages.
- Economic Optimisation: Supported cost estimate and schedule accuracy as key input to financial model refinement, improving confidence in project feasibility and FID readiness.
- Safety and Compliance: Developed detailed safety studies, including HAZID, HAZOP and SIL reviews, ensuring compliance with international standards.
- Strategic Planning: Created an execution plan and contracting framework to facilitate seamless transition into the project’s execution phase.
Through its rigorous and collaborative approach, io ensured the Lancaster Clean Energy Center Phase 1 project progressed towards FID with enhanced technical definition, economic confidence and stakeholder alignment.
