Germany
Green Energy and Steel Imports Reduce Europe's Net-zero Infrastructure Needs
Jun 2025
Publication
Importing renewable energy to Europe may offer many potential benefits including reduced energy costs lower pressure on infrastructure development and less land use within Europe. However open questions remain: on the achievable cost reductions how much should be imported whether the energy vector should be electricity hydrogen or derivatives like ammonia or steel and their impact on Europe’s infrastructure needs. This study integrates a global energy supply chain model with a European energy system model to explore net-zero emission scenarios with varying import volumes costs and vectors. We find system cost reductions of 1-10% within import cost variations of ± 20% with diminishing returns for larger import volumes and a preference for methanol steel and hydrogen imports. Keeping some domestic power-to-X production is beneficial for integrating variable renewables leveraging local carbon sources and power-to-X waste heat. Our findings highlight the need for coordinating import strategies with infrastructure policy and reveal maneuvering space for incorporating non-cost decision factors.
Country Risk Impacts on Export Costs of Green Hydrogen and its Synthetic Downstream Products from the Middle East and North Africa
May 2025
Publication
Green hydrogen produced from renewable energy sources such as wind and solar is increasingly recognized as a critical enabler of the global energy transition and the decarbonization of industrial and transport sectors. The successful adoption of green hydrogen and its derivatives is closely linked to production costs which can vary substantially between countries depending not only on resource potential but also on country-specific financing conditions. These differences arise from country-specific risk factors that affect the costs of capital ultimately influencing investment decisions. However comprehensive assessments that integrate these risks with future cost projections for renewable energy green hydrogen and its synthetic downstream products are lacking. Using the Middle East and North Africa (MENA) as an example this study introduces a novel approach that allows to incorporate mainly qualitative country-specific investment risks into quantitative analyses such as costpotential and energy modelling. Our methodology calculates weighted average costs of capital (WACC) for 17 MENA countries under different risk scenarios providing a more nuanced assessment compared to traditional models that use uniform cost of capital assumptions. The results indicate significant variations in WACC such as between 4.67% in the United Arab Emirates and 24.84% in Yemen or Syria in the business-as-usual scenario. The incorporation of country-specific capital cost scenarios in quantitative analysis is demonstrated by modelling the cost-potential of Fischer-Tropsch (FT) fuels. The results show that countryspecific investment risks significantly impact costs. For instance by 2050 the starting LCOFs in high-risk scenarios can be up to 180% higher than in lowerrisk contexts. This underlines that while renewable energy potential and its cost are important it are the country-specific risk factors—captured through WACC—that have a greater influence in determining the competitiveness of exports and consequently the overall development of the renewable energy green hydrogen and synthetic fuel sectors.
Synergies Between Green Hydrogen and Renewable Energy in South Africa
Aug 2025
Publication
South Africa has excellent conditions for renewable energy generation making it well placed to produce green hydrogen for both domestic use and export. In building a green hydrogen economy around export markets it will face competition from countries with equivalent or better resources and/or that are located closer to export markets (e.g. in North Africa and the Middle East) or have lower capital costs (developed markets like Australia and Canada). South Africa however has an extensive energy system with unserved electricity demand. The ability to trade electricity with the national grid (feeding into the grid during times of peak dedicated renewable energy supply and extracting from the grid during times of low dedicated renewable energy availability) could reduce the cost of producing green hydrogen by as much as 10–25 %. This paper explores the opportunity for South African green hydrogen producers presented by the electricity supply crisis that has been ongoing since 2007. It highlights the potential for a mutually reinforcing growth cycle between renewable energy and green hydrogen to be established which will contribute not only to the mitigation of greenhouse gas emissions but to the local economy and broader society.
Feasibility of Using Rainwater for Hydrogen Production via Electrolysis: Experimental Evaluation and Ionic Analysis
Oct 2025
Publication
This study evaluates the feasibility of employing rainwater as an alternative feedstock for hydrogen production via electrolysis. While conventional systems typically rely on high-purity water—such as deionized or distilled variants—these can be cost-prohibitive and environmentally intensive. Rainwater being naturally available and minimally treated presents a potential sustainable alternative. In this work a series of comparative experiments was conducted using a proton exchange membrane electrolyzer system operating with both deionized water and rainwater collected from different Austrian locations. The chemical composition of rainwater samples was assessed through inductively coupled plasma ion chromatography and visual rapid tests to identify impurities and ionic profiles. The electrolyzer’s performance was evaluated under equivalent operating conditions. Results indicate that rainwater in some cases yielded comparable or marginally superior efficiency compared to deionized water attributed to its inherent ionic content. The study also examines the operational risks linked to trace contaminants and explores possible strategies for their mitigation.
A Comparative Study of Alternative Polymer Binders for the Hydrogen Evolution Reaction
Aug 2025
Publication
Given the economic industrial and environmental value of green dihydrogen (H2) optimization of water electrolysis as a means of producing H2 is essential. Binders are a crucial component of electrocatalysts yet they remain largely underdeveloped with a significant lack of standardization in the field. Therefore targeted research into the development of alternative binder systems is essential for advancing performance and consistency. Binders essentially act as the key to regulating the electrode (support)–catalyst–electrolyte interfacial junctions and contribute to the overall reactivity of the electrocatalyst assembly. Therefore alternative binders were explored with a focus on cost efficiency and environmental compatibility striving to achieve desirable activity and stability. Herein the alkaline hydrogen evolution reaction (HER) was investigated and the sluggish water dissociation step was targeted. Controlled hydrophilic poly(vinyl alcohol)-based hydrogel binders were designed for this application. Three hydrogel binders were evaluated without incorporated electrocatalysts namely PVA145 PVA145-blend-bPEI1.8 and PVA145-blend-PPy. Interestingly the study revealed that the hydrophilicity of the binders exhibited an enhancing effect on the observed activity resulting in improved performance compared to the commercial binder Nafion™. Notably the PVA145 system stands out with an overpotential of 224 mV at−10 mA·cm−2 (geometric) in 1.0 M KOH compared to the 238 mV exhibited by Nafion™. Inclusion of Pt as active material in PVA145 as binder exhibited a synergistic increase in performance achieving a mass activity of 1.174 A.cm−2.mg−1 Pt in comparison to Nafion™’s 0.344 A.cm−2.mg−1 Pt measured at−150 mV vs RHE. Our research aimed to contribute to the development of cost-effective and efficient binder systems stressing the necessity to challenge the dominance of the commercially available binders.
Process Integration and Exergy-based Assessment of High-temperature Solid Oxide Electrolysis Configurations
Sep 2025
Publication
Solid oxide electrolysis (SOEL) is considered an efficient option for largely emission-free hydrogen production and thus for supporting the decarbonization of the process industry. The thermodynamic advantages of high-temperature operation can be utilized particularly when heat integration from subsequent processes is realized. As the produced hydrogen is usually required at a higher pressure level the operating pressure of the electrolysis is a relevant design parameter. The study compares pressurized and near-atmospheric designs of 126 MW SOEL systems with and without the integration of process heat from a downstream ammonia synthesis and the inefficiencies that occur in the processes. Furthermore process improvements by sweep-air utilization are investigated. Pinch analysis is applied to determine the potential of internal heat recovery and the minimum external heating and cooling demand. It is shown that pressurized SOEL operation does not necessarily decrease the overall power consumption for compression due to the high power requirement of the sweep-air compressor. The exergetic efficiencies of the standalone SOEL processes achieve similar values of = 81 %. Results further show that integrating the heat of reaction from ammonia synthesis can replace almost the entire electrically supplied thermal energy thereby improving the overall exergetic efficiency by up to 3.5 percentage points. However the exergetic efficiency strongly depends on the applied air ratio. The highest exergetic efficiency of 86 % can be achieved by employing sweep-air utilization with an expander. The results demonstrate that integrating downstream process heat and applying sweep-air utilization can significantly enhance overall efficiency and thus reduce external energy requirements.
Increasing Public Acceptance of Fuel Cell Vehicles in Germany: A Perspective on Pioneer Users
Jun 2025
Publication
Fuel cell vehicles (FCVs) represent an intriguing alternative to battery electric vehicles (BEVs). While the acceptance of BEVs has been widely discussed acceptance-based recommendations for promoting adoption of FCVs remain ambiguous. This paper aims to improve our understanding by reporting results from a pioneer study based on the standardized Unified Theory of Acceptance and Use of Technology 2 (UTAUT2). The sample consists of n1 = 258 registered customers of H2mobility in Germany. For effect control another n2 = 294 participant sample was drawn from the baseline population. Data were analyzed using SmartPLS 4 and importance-performance mapping (IPMA). Results demonstrate that FCV acceptance primarily relies on Perceived Usefulness Perceived Conditions and Normative Influence while surprisingly hypotheses involving Perceived Risk and Green Attitude are rejected. Finally a discussion reveals ways to increase the level of public acceptance. Three practical strategies emerge. For future acceptance analyses the authors suggest incorporating the young concept of ‘societal readiness’.
Alternative Fuels in Aero Engine Performance Calculations
Oct 2025
Publication
This paper presents a method for gas turbine performance calculations with alternative fuels with a particular focus on their use in aircraft engines. The effects of various alternative aviation fuels on fuel consumption CO2 emissions and contrail formation are examined in a comparative study. We use the GasTurb performance software and calculate heat release and hot section gas properties using a chemical equilibrium solver. Fuels with complex compositions are included in the calculation via surrogates of a limited number of known species that mimic the relevant properties of the real fuel. An automated method is used for the fuel surrogate formulation. We compare the results of this rigorous approach with the simplified approach of calculating the heat release using an alternative fuel’s heating value while still using the gas properties of conventional Jet A-1. The results show that the latter approach systematically overpredicts fuel consumption by up to 0.2% for aromaticsfree synthetic kerosene (e.g. “biofuels”). Overall aircraft engines running on alternative fuels tend to be more fuel efficient due to their often higher hydrogen contents and thus fuel heating values. We find reductions in fuel consumption of up to 2.8% during cruise when using aromatics-free synthetic kerosene. We further assess how alternative fuels affect contrail formation based on the Schmidt-Appleman criterion. Contrails can form 200 m lower under cruise conditions when burning aromatics-free synthetic kerosene instead of Jet A-1 with identical thrust requirements and under the same atmospheric conditions mainly due to their higher hydrogen content. In summary we present a flexible yet easy-to-use method for studying fuel effects in performance calculations that avoids small but systematic errors by rigorously calculating the heat release and hot section gas properties for each fuel.
Exploring the Potential of Ammonia as a Fuel: Advances in Combustion Understanding and Large-scale Furnace Applications
Sep 2025
Publication
From an environmental standpoint carbon-free energy carriers such as ammonia and hydrogen are essential for future energy systems. However their hightemperature chemical behavior remains insufficiently understood posing challenges for the development and optimization of advanced combustion technologies. Ammonia in particular is globally available and cost-effective especially for energy-intensive industries. The addition of ammonia or hydrogen to methane significantly reduces the accuracy of existing predictive models. Therefore validated and detailed data are urgently needed to enable reliable design and performance predictions. This review highlights the compatibility of ammonia with existing combustion infrastructure facilitating a smoother transition to more sustainable heating methods without the need for entirely new systems. Applications in high-temperature heating processes such as metal processing ceramics and glass production and power generation are of particular interest. This review focuses on the systematic assessment of alternative fuel mixtures comprising ammonia and hydrogen as well as natural gas with particular consideration of existing safety-related parameters and combustion characteristics. Fundamental quantities such as the laminar burning velocity are discussed in the context of their relevance for fuel mixtures and their scalability toward turbulent flame propagation which is of critical importance for industrial burner and reactor design. The influence of fuel composition on ignition limits is examined as these are essential parameters for safety margin definitions and operational boundary conditions. Furthermore flame stability in mixed-fuel systems is addressed to evaluate the practical feasibility and robustness of combustion under varying process conditions. A detailed overview of current diagnostic and analysis methods follows encompassing both pollutant measurement techniques and the detection of key radical species. These diagnostics form the experimental basis for reaction kinetics modeling and mechanism validation. Given the importance of emission formation in combustion systems a dedicated subsection summarizes major emission trends even though a comprehensive treatment would exceed the scope of this review. Thermal radiation effects which are highly relevant for heat transfer and system efficiency in large-scale applications are then reviewed. In parallel current developments in numerical simulation approaches for industrial-scale combustion systems are presented including aspects of model accuracy boundary conditions and computational efficiency. The review also incorporates insights from materials engineering particularly regarding high-temperature material performance corrosion resistance and compatibility with combustion products. Based on these interdisciplinary findings operational strategies for high-temperature furnaces are outlined and selected industrial reference systems are briefly presented. This integrated approach aims to support the design optimization and safe operation of next-generation combustion technologies utilizing carbon-free or low-carbon fuels.
Catalytic Hydrogen Combustion as Heat Source for the Dehydrogenation of Liquid Organic Hydrogen Carriers using a Novel Compact Autothermal Reactor
Sep 2025
Publication
The experimental performance of an autothermal hydrogen release unit comprising a perhydro benzyltoluene (H12-BT) dehydrogenation chamber and a catalytic hydrogen combustion (CHC) chamber in thermal contact is discussed. In detail the applied set-up comprised a multi-tubular CHC heating based on seven parallel tubes with the reactor shell containing a commercial dehydrogenation catalyst. In this way the CHC heated the endothermal LOHC dehydrogenation using a part of the hydrogen generated in the dehydrogenation. The proposed heating concept for autothermal LOHC dehydrogenation offers several advantages over state-of-the-art heating concepts including minimized space consumption high efficiency and zero NOx emissions. During performance tests the process reached a minimum hydrogen combustion fraction of 37 % while the minimum heat requirement for the dehydrogenation reaction for industrial scale plants is 33 %. The reactor orientation (vertical vs horizontal) and the flow configuration (counter-current vs. co-current) showed very little influence on the performance demonstrating the robustness of the proposed reactor design.
The Need for Change: A Roadmap for the Sustainable Transformation of the Chemical Industry
Jun 2025
Publication
The chemical industry faces major challenges worldwide. Since 1950 production has increased 50-fold and is projected to continue growing particularly in Asia. It is one of the most energy- and resource-intensive industries contributing significantly to greenhouse gas emissions and the depletion of finite resources. This development exceeds planetary boundaries and calls for a sustainable transformation of the industry. The key transformation areas are as follows: (1) Non-Fossil Energy Supply: The industry must transition away from fossil fuels. Renewable electricity can replace natural gas while green hydrogen can be used for high-temperature processes. (2) Circularity: Chemical production remains largely linear with most products ending up as waste. Sustainable product design and improved recycling processes are crucial. (3) Non-Fossil Feedstock: To achieve greenhouse gas neutrality oil gas and coal must be replaced by recycling plastics renewable biomaterials or CO2-based processes. (4) Sustainable Chemical Production: Energy and resource savings can be achieved through advancements like catalysis biotechnology microreactors and new separation techniques. (5) Sustainable Chemical Products: Chemicals should be designed to be “Safe and Sustainable by Design” (SSbD) meaning they should not have hazardous properties unless essential to their function. (6) Sufficiency: Beyond efficiency and circularity reducing overall material flows is essential to stay within planetary boundaries. This shift requires political economic and societal efforts. Achieving greenhouse gas neutrality in Europe by 2050 demands swift and decisive action from industry governments and society. The speed of transformation is currently too slow to reach this goal. Science can drive innovation but international agreements are necessary to establish a binding framework for action.
Overcoming Hurdles and Harnessing the Potential of the Hydrogen Transition in Germany
Jun 2025
Publication
Green hydrogen has become a core element of Europe’s energy transition to assist in lowering carbon emissions. However the transition to green hydrogen faces challenges including the cost of production availability of renewable energy sources public opposition and the need for supportive government policies and financial initiatives. While there are other alternatives for producing low-carbon hydrogen for example blue hydrogen German funding favours projects that involve hydrogen production via electrolysis. Beyond climate goals it is anticipated that a green hydrogen industry will create economic benefits and a wide-range of collaborative opportunities with key international partnerships increasing energy security if done appropriately. Germany a leader in green hydrogen technology will need to rely on imports to meet long-term demand due to limited renewable energy capacity. Despite the current obstacles to transitioning to green hydrogen it is felt that ultimately the benefits of this industry and reducing emissions will outweigh the associated costs of production. This study analyses the hydrogen transition in Germany by interviewing 37 European experts guided by the research question: What are the key perceived barriers and opportunities influencing the successful adoption and integration of hydrogen technologies in Germany’s hydrogen transition?
Preliminary Design of Regional Aircraft—Integration of a Fuel Cell-Electric Energy Network in SUAVE
Mar 2025
Publication
To enable climate-neutral aviation improving the energy efficiency of aircraft is essential. The research project Synergies of Highly Integrated Transport Aircraft investigates cross-disciplinary synergies in aircraft and propulsion technologies to achieve energy savings. This study examines a fuel cell electric powered configuration with distributed electric propulsion. For this a reverse-engineered ATR 72-500 serves as a reference model for calibrating the methods and ensuring accurate performance modeling. A baseline configuration featuring a state-of-the-art turboprop engine with the same entry-into-service is also introduced for a meaningful performance comparison. The analysis uses an enhanced version of the Stanford University Aerospace Vehicle Environment (SUAVE) a Python-based aircraft design environment that allows for novel energy network architectures. This paper details the preliminary aircraft design process including calibration presents the resulting aircraft configurations and examines the integration of a fuel cell-electric energy network. The results provide a foundation for higher fidelity studies and performance comparisons offering insights into the trade-offs associated with hydrogen-based propulsion systems. All fundamental equations and methodologies are explicitly presented ensuring transparency clarity and reproducibility. This comprehensive disclosure allows the broader scientific community to utilize and refine these findings facilitating further progress in hydrogen-powered aviation technologies.
Injection Strategies in a Hydrogen SI Engine: Parameter Selection and Comparative Analysis
Oct 2025
Publication
Injection strategies play a crucial role in determining hydrogen engine performance. The diversity of these strategies and the limited number of comparative studies highlight the need for further investigation. This study focuses on the analysis parameter selection and comparison of single early and late direct injection single injection with ignition occurring during injection (the so-called jet-guided operation) and dual injection in a hydrogen spark-ignition engine. The applicability and effectiveness of these injection strategies are assessed using contour maps with ignition timing and start of injection as coordinates representing equal levels of key engine parameters. Based on this approach injection and ignition settings are selected for a range of engine operating modes. Simulations of engine performance under different load conditions are carried out using the selected parameters for each strategy. The results indicate that the highest indicated thermal efficiencies are achieved with single late injection while the lowest occur with dual injection. At the same time both dual injection and jet-guided operation provide advantages in terms of knock suppression peak pressure reduction and reduced nitrogen oxide emissions.
A Proposal of Hydrogen Safety Technology for Decommissioning of the Fukushima Daiichi Nuclear Power Station
Mar 2025
Publication
The safe removal transportation and long-term storage of fuel debris in the decommissioning of Fukushima Daiichi is the biggest challenge facing Japan. In the nuclear power field passive autocatalytic recombiners (PARs) have become established as a technology to prevent hydrogen explosions inside the containment vessel. To utilize PAR as a measure to reduce the concentration of hydrogen generated in the fuel debris storage canister which is currently an issue it is required to perform in a sealed environment with high doses of radiation low temperature and high humidity and there are many challenges different from conventional PAR. A honeycombshaped catalyst based on automotive catalyst technology has been newly designed as a PAR and research has been conducted to solve unique problems such as high dose radiation low temperature high humidity coexistence of hydrogen and low oxygen and catalyst poisons. This paper summarizes the challenges of hydrogen generation in a sealed container the results of research and a guide to how to use the PAR for fuel debris storage canisters.
Who Is in and How? A Comprehensive Study on Stakeholder Perspectives in the Green Hydrogen Sector in Luxembourg
Oct 2025
Publication
Green hydrogen has the potential to contribute to the decarbonization of the fossil fuel industry and its development is expected to increase in the coming years. The social dynamics among the various actors in the green hydrogen sector are studied to understand their public perception. Using the technological innovation system research approach for the stakeholder analysis and the qualitative thematic analysis method for the interviews with experts this study presents an overview of the actors in the green hydrogen sector and their relations in Luxembourg. As a central European country with strategic political and geographic relevance Luxembourg offers a timely case for analyzing public perception before the large-scale implementation of green hydrogen. Observing this early stage allows for future comparative insights as the national hydrogen strategy progresses. Results show high expectations for green hydrogen in mobility and industry but concerns persist over infrastructure costs safety and public awareness. Regional stakeholders demonstrate a strong willingness to collaborate recognizing that local public acceptance still requires effort particularly in areas such as clear and inclusive communication sharing knowledge and fostering trust. These findings provide practical insights for stakeholder engagement strategies and theoretical contributions to the study of social dynamics in sustainability transitions.
A Decision-support Flowchart for Including Parameter Uncertainty in Prospective Life Cycle Inventory Modeling: An Application to a PEM Fuel Cell-based APU System for a Hydrogen-powered Aircraft
Oct 2025
Publication
Emerging energy technologies offer significant opportunities for climate change mitigation. However the assessment of their potential environmental impact through prospective life cycle assessment (pLCA) is challeng‑ ing owing to parameter uncertainties arising from data gaps temporal variability and evolving technological contexts when modeling their prospective life cycle inventories (pLCI). Existing methodologies lack standardized approaches for systematically integrating parameter uncertainty within pLCI frameworks often initially overlooking it. In order to fill this gap this study proposes a structured and transparent approach for incorporating parameter uncertainty directly into the pLCI modeling process. The goal is to enhance the robustness transparency and reproducibility of pLCI models. A decision–support flowchart based on an adapted six-step framework was developed to help life cycle assessment (LCA) practitioners address parameter uncertainty during the “goal and scope definition” and“life cycle inventory” phases of pLCA. The flowchart guides users through the process of defining of the assessment’s goal scope as well as its temporal and geographical boundaries and the technology’s maturity level (Step 1). Step 2 entails gathering data to depict the technology’s development. Steps 3 and 4 involve identifying parameters that are likely to change in the future such as manufacturing processes materials equipment and component dimensions as well as their respective uncertainties. Step 5 includes the learning effects required for industrial-scale production once the technology has reached maturity. Finally step 6 identifies external developments impacting the technology as well as contributing uncertainties. A case study of a fuel cell-based propulsion system for a hydrogen-powered aircraft in 2040 illustrates the applicability of the framework. This study introduces a structured flowchart to support decision making in cases when parameter uncertainty should be integrated into pLCI modeling. By supporting the selection of appropriate prospective meth‑ ods as well as uncertainty identification and characterization strategies the proposed flowchart enhances the trans‑ parency consistency and representativeness of the pLCA results facilitating their broader application in emerging technology assessment methods.
Life Cycle Assessment of Future Electricity and Hydrogen Systems: Implications for Low-carbon Transport
Oct 2025
Publication
This study develops and applies a life cycle assessment (LCA) framework combined with predictive market models to evaluate the environmental impacts of electricity and hydrogen for transport in the EU27+UK from 2020 to 2050. By linking evolving power sector scenarios with hydrogen supply models we assess the wellto-wheels (WTW) performance of battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs) under consistent energy assumptions. Results show that electricity decarbonization can reduce GWP by up to 80% by 2050 but increases land use and mineral/metal demand due to renewable infrastructure expansion. The environmental impacts of hydrogen production are strongly influenced by the electricity mix especially in high electrolysis scenarios. WTW analysis indicates that while BEVs consistently achieve lower WTW GWP than FCEVs across all scenarios both drivetrains exhibit notable trade-offs in other impact categories. Scenarios dominated by blue hydrogen although not optimal in terms of GWP present a more balanced environmental profile making them a viable transitional pathway in contexts that prioritize minimizing other environmental impacts.
Advancing the Energy Transition in the Steel Industry: A Game-theoretic Bilevel Approach for Green Hydrogen Supply Chains
Sep 2025
Publication
Green hydrogen is essential for advancing the energy transition as it is regarded as a CO2-neutral flexible and storable energy carrier. Particularly in steel production which is known for its high energy intensity hydrogen has great potential to replace conventional energy sources. In a game-theoretic bi-level optimization model involving a power plant operator and a steel company we investigate in which situations the production and use of green hydrogen is advantageous from an economic and ecological point of view. Through an extensive case study based on a realworld scenario we can observe that hydrogen production can serve as a profitable and flexible secondary income opportunity for the power plant operator and help avoid curtailment and spot market losses. On the other hand the steel manufacturer can reduce CO2 emissions and associated costs while also meeting the growing customer demand for low-carbon products. However our findings also highlight important trade-offs and uncertainties. While lower electricity generation costs or improved electrolyzer efficiency enhance hydrogen’s competitiveness increases in coal and CO2 emission prices do not always result in greater hydrogen adoption. This is due to the persistent reliance on a non-replaceable share of coal in steel production which raises the overall cost of both low-carbon and carbon-intensive steel. The model further shows that consumer demand elasticity plays a critical role in determining hydrogen uptake. These insights underscore the importance of not only reducing hydrogen costs but also designing supportive policies that address market acceptance and the full cost structure of green industrial products.
Modeling and Experimental Approach of Membrane and Diaphragm Sono-electrolytic Production of Hydrogen
Oct 2025
Publication
This study evaluates the performance of three anion-exchange membranes (FAS-50 AMX Fujifilm-AEM) and a diaphragm separator (Zirfon® UTP 500) in alkaline water sono-electrolysis using a 25 % KOH electrolyte at ambient temperature. Energy efficiency hydrogen production kinetics and membrane stability were assessed experimentally and through modeling. Among the tested separators Zirfon achieved the highest energy efficiency outperforming AEM AMX and FAS-50. Hydrogen production rates under silent conditions ranged from 2.55 µg/s (AEM) to 2.92 µg/s (FAS-50) while sonication (40 kHz 60 W) increased rates by 0.03–0.12 µg/s with the strongest relative effect observed for FAS-50 (≈4.0 % increase). By contrast Zirfon and AEM showed slight efficiency reductions (0.5–2 %) under ultrasound due to their higher structural resistance. Ion-exchange capacity tests confirmed significant degradation of polymeric membranes (IEC losses of 60–90 %) while Zirfon maintained stability in 25 % KOH. Modeling results showed that the diaphragm resistance was dominated by the ohmic losses (55–86 %) with ultrasound reducing bubble coverage and associated resistance only marginally (<0.02 V). Overall Zirfon demonstrated superior stability and efficiency for long-term operation while ultrasound primarily enhanced hydrogen evolution kinetics in mechanically weaker polymeric membranes.
Evaluation of Heat Transfer Technologies for High Temperature Polymer Electrolyte Membrane Fuel Cells as Primary Power Source in a Regional Aircraft
Oct 2025
Publication
High-temperature proton exchange membrane fuel cells (HT-PEM FCs) represent a promising avenue for generating carbon dioxide-free electricity through the utilization of hydrogen fuel. These systems present numerous advantages and challenges for mobile applications positioning them as pivotal technologies for the realization of emission-free regional aircraft. Efficient thermal management of such fuel cell-powered systems is crucial for ensuring the safe and durable operation of the aircraft while concurrently optimizing system volume mass and minimizing parasitic energy consumption. This paper presents four distinct heat transfer principles tailored for the FC-system of a conceptual hydrogen-electric regional aircraft exemplified by DLR’s H2ELECTRA. The outlined approaches encompass conductive cooling air cooling liquid cooling phase change cooling and also included is the utilization of liquid hydrogen as a heat sink. Approaches are introduced with schematic cooling architectures followed by a comprehensive evaluation of their feasibility within the proposed drivetrain. Essential criteria pertinent to airborne applications are evaluated to ascertain the efficacy of each thermal management strategy. The following criteria are selected for evaluation: safety ease of integration reliability and life-cycle costs technology readiness and development as well as performance which is comprised of heat transfer weight volume and parasitic power consumption. Of the presented cooling methods two emerged to be functionally suitable for the application in MW-scale aircraft applications at their current state of the art: liquid cooling utilizing water under high pressure or other thermal carrier liquids and phase-change cooling. Air cooling and conductive cooling have a high potential due to their reduced system complexity and mass but additional studies investigating effects at architecture level in large-scale fuel cell stacks are needed to increase performance levels. These potentially suitable heat transfer technologies warrant further investigation to assess their potential for complexity and weight reduction in the aircraft drivetrain.
Applied Simulation Study of a Metal Hydride Refrigeration System for Fuel Cell Trucks
Oct 2025
Publication
Refrigeration units in semi-trucks or rigged-body trucks have an energy demand of 8.2–12.4 MWh/y and emit 524.26 kt CO2e/y in Germany. Electrification with fuel cell systems reduces the CO2 emission but an increase of efficiency is necessary because of rapidly increasing hydrogen costs. A metal hydride refrigeration system can increase the efficiency. Even though it was already demonstrated in lab scale with 900 W this power is not sufficient to support a truck refrigeration system and the power output of the lab system was not controllable. Here we show the design and validation of a MATLAB© Simulink model of this metal hydride refrigeration system and its suitability for high power applications with a scaled-up reactor. It was scaled up to rated power of 5 kW and efficiency improvements with an advanced valve switching as well as a controlled cooling pump were implemented. Two application-relevant use cases with hydrogen mass flows from hydrogen fuel cell truck systems were analyzed. The simulation results of these use cases provide an average cooling power of 4.2 and 6.1 kW. Additionally the control of the coolant mass flow at different temperature levels a controlled hydrogen mass flow with a bypass system and an advanced valve switching mechanism increased the system efficiency of the total refrigeration system by 30 % overall.
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