Scalable model for future green hydrogen delivery

The HyBont Green Hydrogen Project in Bridgend, Wales, focused on generating green hydrogen from solar and wind for transportation and local industry. The £30M project was one of the first onshore green hydrogen projects from the UK government’s Hydrogen Allocation Round One (HAR1) funding and is a potential model project for hydrogen production in the UK.

Final planning approval was granted in 2025, following on from four years of work by Mott MacDonald acting in capacity as the owner’s engineer for Marubeni Europower. The team, headed up by Mott MacDonald hydrogen, carbon capture and storage (CCS) and LNG lead, Jamie Paul, developed the design of the hydrogen production and refuelling facility alongside an associated solar photovoltaic (PV) plant.

“As one of the first of its kind, our task was to ensure the project was feasible,” explains Jamie. “HyBont, a HAR1 short-listed project, combines solar generation, private wire and hydrogen production and storage. It is an exemplar green hydrogen project that could be replicated across the country to decarbonise local industry and transportation.”

Collaborative development

The planned scheme on Brynmenyn Industrial Estate was designed to feature an electrolyser plant capable of producing between 500t and 850t of green hydrogen annually. Partially powered by a nearby 5.5MWp solar PV farm at Bryncethin via a private connection, the project would also use additional renewable energy sourced from wind farms connected through the National Grid.

Jamie’s team undertook the engineering design of the hydrogen production and refuelling facility and solar farm. The team worked in parallel with planning consultant RPS and supported Marubeni with its funding applications and interfaces with the water supply, electricity and other utilities, in preparation for the planning application.

“We designed the site layout, drainage systems and the solar facility to power the electrolyser, alongside process flow diagrams, heat and material balances and defined key parameters such as temperature, pressure and flow rates,” explains Jamie.

The team also assessed the civil works required, including road access, site preparation, utility searches, geophysical surveys and geotechnical investigations to gain a thorough understanding of site conditions.

“We were able to draw on our extensive engineering expertise to support Marubeni, using our knowledge gained from working on other green hydrogen projects in the UK, including the Cromarty and Speyside hydrogen schemes. For HyBont, we consolidated this experience and delivered a full range of end-to-end services to support the project,” adds Jamie.

Solutions for brownfield sites

The design anticipated hydrogen use for powering local refuse collection vehicles and buses near Brynmenyn Industrial Estate, as well as export by tube trailers to industrial consumers.

“This made the location of the production and refuelling facility both convenient and cost-effective for end users,” explains Jamie. “The Hybont site was designed to provide storage to allow for intermittency of renewable power and variations in hydrogen demand.”

The site was also chosen for its proximity to the solar array at Bryncethin. “Solar energy was a key component of green hydrogen production at Hybont and a direct power connection from the solar farm to the electrolyser was critical to the operation,” says Jamie. “It would ensure recovery of 100% renewable energy produced nearby, supplemented by wind power through the National Grid.”

Focusing on safety

To ensure development and operations would not negatively impact the surrounding environment, the team conducted comprehensive safety assessments focussing on the potential effects of hydrogen. Hazardous substance consent was secured as part of the design process.

The site layout was designed so workers would spend less time in hazardous areas, with offices and rest areas located furthest away. As part of this work, Jamie’s team ensured the layout allowed for the safe entry and exit of heavy vehicles refuelling on hydrogen.

“Hydrogen safety is always a key focus, and we ensured compliance with all relevant standards and best practices,” adds Jamie.

Contractor call for tender package

“Our initial design went to the market to look for a FEED and EPC contractor with the skills and expertise to carry it forward to final design,” says Jamie. “Clarke Energy was selected and has further developed our initial design with our team reviewing the FEED design as it progressed.

“I’m proud of what the team has achieved for the HyBont scheme. The team provided end-to-end support, helping Marubeni move from concept to a fully scoped and technically sound project,” says Jamie. “We’ve built strong experience in green hydrogen, and our expertise included all supporting disciplines needed – civil, mechanical, electrical, environmental and social.

“Hydrogen production isn’t new; but integrating it into a modern infrastructure context in the way we have at HyBont is complex. Clients come to us with a site and funding, and we help shape that project.

“HyBont was designed as a catalyst for innovation in the Welsh hydrogen sector. This pioneering project has demonstrated a very scalable model for clean hydrogen production that could be used locally and replicated across the UK,” adds Jamie.