| Client | Hydrostor |
| Project | PreFEED Optimisation of Advanced Compressed Air Energy Storage System |
| Sector | Resource Infrastructure |
| Services | FEL2a – Concept Select & Owners Engineer |
| Location | Global |
Objective
Hydrostor, a leading energy storage company, engaged io consulting to optimise its Advanced Compressed Air Energy Storage (A-CAES) system at a PreFEED level. The goal was to enhance system efficiency, reduce capital costs, and establish a robust design basis for future large-scale projects. (image courtesy of Hydrostor Inc.)
Project Scope
The PreFEED Optimisation Study (PFOS) was conducted in four phases:
- Phase 1 – Focused on optimising the Thermal Management System and heat exchanger selection.
- Phase 2 – Evaluated turbomachinery configurations and their economic scalability.
- Phase 3 – Identified key cost reduction opportunities, particularly in heat exchanger performance and efficiency trade-offs.
- Phase 4 – Assessed alternative turbomachinery options and refined system designs for improved performance and cost-effectiveness.
Key activities included system engineering, technical modelling, thermal management assessment, material selection and constructability analysis.
Findings & Recommendations
The PreFEED Optimisation Study identified several opportunities to enhance the technical robustness, scalability and commercial viability of Hydrostor’s Advanced Compressed Air Energy Storage (A-CAES) system.
The study assessed a range of system configurations, technology options and integration strategies to support future large-scale deployment and long-term operational performance. Key areas of focus included thermal management, turbomachinery configuration, constructability, operational resilience and overall system integration.
The work undertaken by io consulting supported:
- Evaluation of alternative process and equipment configurations to improve system operability and lifecycle performance.
- Identification of engineering approaches to support efficient integration between subsurface and topsides systems.
- Assessment of technology selection considerations, balancing performance, constructability, maintainability and commercial drivers.
- Review of opportunities to simplify installation and execution strategies through modularisation and standardisation principles.
- Development of operational risk mitigation strategies to enhance long-term reliability and system stability.
- Establishment of a robust technical basis to support future project development and scalability across multiple geographies.
The study also considered emerging technologies and future optimisation pathways to support continued innovation and flexibility as the A-CAES market matures.
io Value Add
io consulting’s expertise in system modelling, cost optimisation and risk mitigation was instrumental in defining a technically sound and commercially viable A-CAES concept. Key contributions included:
- Cost-Optimised Engineering – Identifying the optimal balance between efficiency and CAPEX, enabling Hydrostor to maintain a competitive position.
- Innovative Technology Development – Collaborating with Hydrostor to develop and patent a novel solution to mitigate the champagne effect, ensuring reliable cavern operation.
- Vendor Engagement & Technology Selection – Ensuring robust equipment selection through rigorous evaluation of turbomachinery and heat exchanger options.
- Risk Mitigation & Technical Safety – Addressing critical operational risks, including thermal cycling impacts, cavern integrity, and overpressure safety.
- Constructability Strategy – Developing modular construction methodologies to streamline project execution.
The PFOS successfully refined Hydrostor’s A-CAES design, establishing a lower-cost, high-efficiency pathway for future deployment. The insights from this study will guide Hydrostor in scaling its technology for commercial projects worldwide, with a focus on optimised thermal management, efficient turbomachinery selection, and cost-effective system integration.
This study positioned Hydrostor for cost-effective expansion in the global energy storage market, reinforcing A-CAES as a key solution for large-scale grid stability. Two projects are underway in The United States of America and Australia with io consulting assigned as Owners Engineer.
