HySEA · Project

Explosion-Proof Your Hydrogen Facility with Validated Safety Software and Vent Sizing Rules

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When you store hydrogen in a container or building, there's always a risk it could ignite and explode. Think of it like a pressure cooker — you need a relief valve sized just right, or things go very wrong. HySEA ran full-scale explosion tests inside real shipping containers, then built computer software that predicts exactly how big the explosion pressure will be and what size vent you need to keep people safe. The results feed directly into the safety standards that regulators use across Europe and the US.

By the numbers

total project deliverables produced

demo deliverables including software releases and explosion tests

EUR 1,494,780

EU contribution to the project

consortium partners across 5 countries

43%

industry participation ratio in the consortium

The business problem

What needed solving

Hydrogen is critical for the energy transition, but storing and handling it in enclosed spaces creates serious explosion risks. Companies building hydrogen infrastructure must prove their facilities are safe — yet current venting standards are outdated and physical explosion testing is expensive, dangerous, and slow. Without reliable prediction tools and clear vent sizing rules, projects face permitting delays, excessive safety margins that inflate costs, or worse, inadequate protection.

The solution

What was built

The project delivered two validated explosion prediction software tools (FLACS-Hydrogen and HyFOAM, each with two releases), full-scale experimental data from vented deflagration tests in ISO containers, engineering models for quick vent sizing calculations, pressure-impulse diagrams for typical structures, and concrete recommendations for improving European and American explosion venting standards.

Audience

Who needs this

Hydrogen refueling station developers needing explosion safety certificationIndustrial gas companies designing hydrogen storage facilitiesSafety engineering consultancies advising on explosion ventingInsurance companies assessing hydrogen facility risksRegulators and standards bodies updating explosion venting codes

Business applications

Who can put this to work

Hydrogen storage and distribution

mid-size

Target: Companies building or operating hydrogen refueling stations, electrolysis plants, or storage depots

If you are a hydrogen infrastructure operator dealing with explosion risk assessments for permitting and insurance — this project developed validated CFD software (FLACS-Hydrogen and HyFOAM) and engineering models that predict explosion pressures in enclosed spaces. These tools can replace expensive physical testing and speed up your safety certification process, backed by 53 deliverables of experimental validation data.

Industrial gas and chemical processing

enterprise

Target: Chemical plants and gas companies handling hydrogen in enclosed facilities

If you are a chemical plant manager responsible for explosion protection in warehouses or process buildings — this project produced pressure-impulse diagrams and vent sizing recommendations validated against full-scale ISO container tests. The tools let you design cost-effective venting systems that meet both European EN-14994 and American NFPA 68 standards without over-engineering.

Safety engineering and consulting

SME

Target: Engineering consultancies specializing in explosion protection and industrial safety

If you are a safety consultancy that advises clients on explosion venting design — this project delivered two validated software tools and blind-prediction benchmarks that your engineers can use to provide defensible, standards-compliant vent sizing recommendations. The consortium of 7 partners across 5 countries tested these tools against real explosion data, giving your analyses stronger credibility with regulators.

Frequently asked

Quick answers

What would it cost to use HySEA's software tools?

FLACS-Hydrogen is developed by GEXCON AS, the project coordinator, which is a commercial software company. Licensing terms would need to be discussed directly with GEXCON. HyFOAM is based on the open-source OpenFOAM platform, which may offer a lower-cost entry point.

Can these tools handle real industrial-scale facilities, not just lab tests?

Yes. The experimental program used full-scale standard ISO containers with obstacle configurations representing real industrial congestion levels. The project also specifically used validated CFD codes to explore explosion hazards in larger enclosures such as warehouses, going beyond the test containers.

What about IP and licensing for the software?

FLACS-Hydrogen is proprietary software owned by GEXCON AS (Norway). HyFOAM had two software releases during the project and is likely available under different terms. Contact GEXCON or the relevant consortium partner for licensing details.

Do these results align with current safety regulations?

The project was specifically designed as pre-normative research to improve European (EN-14994), American (NFPA 68), and other relevant explosion venting standards. The recommendations produced are intended to feed directly into the next revisions of these standards, making early adoption a strategic advantage.

How mature is this technology — can I use it now?

Both FLACS-Hydrogen and HyFOAM went through two software releases during the project. GEXCON's FLACS platform is already a commercially deployed explosion modeling tool used worldwide, and the hydrogen-specific improvements from HySEA have been integrated into it. The project ended in November 2018, so these tools have had years of additional development since.

How does this integrate with our existing safety assessment workflow?

The project developed a hierarchy of models from simple engineering calculations to full CFD simulations. This means you can use quick engineering models for screening assessments and bring in the CFD tools for detailed analysis — fitting into standard tiered safety assessment approaches.

Consortium

Who built it

The HySEA consortium brings together 7 partners from 5 countries (Belgium, China, Italy, Norway, UK), with a strong 43% industry ratio — 3 industrial partners alongside 4 universities. The coordinator GEXCON AS is a Norwegian commercial company specializing in explosion safety software, which means the research results have a direct commercial owner with existing sales channels. The international spread and mix of industry plus academia gives the outputs both scientific credibility and practical market relevance. The inclusion of a Chinese partner also signals applicability beyond Europe.

GEXCON ASCoordinator · NO
University of Science and Technology of Chinaparticipant · CN
UNIVERSITA DI PISAparticipant · IT
UNIVERSITY OF WARWICKparticipant · UK

How to reach the team

GEXCON AS is a well-known safety consultancy and software company based in Bergen, Norway. Their team is reachable through gexcon.com.

Order a report on this consortium See GEXCON AS profile →

Next steps

Talk to the team behind this work.

Want an introduction to the HySEA team for explosion safety software or vent sizing consulting? SciTransfer can arrange a direct connection.

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