Italy
Hydrogen Cost and Carbon Analysis in Hollow Glass Manufacturing
Aug 2025
Publication
The European Union promotes decarbonization in energy-intensive industries like glass manufacturing. Collaboration between industry and researchers focuses on reducing CO2 emissions through hydrogen (H2) integration as a natural gas substitute. However to the best of the authors’ knowledge no updated real-world case studies are available in the literature that consider the on-site implementation of an electrolyzer for autonomous hydrogen production capable of meeting the needs of a glass manufacturing plant within current technological constraints. This study examines a representative hollow glass plant and develops various decarbonization scenarios through detailed process simulations in Aspen Plus. The models provide consistent mass and energy balances enabling the quantification of energy demand and key cost drivers associated with H2 integration. These results form the basis for a scenario-specific techno-economic assessment including both on-grid and off-grid configurations. Subsequently the analysis estimates the levelized costs of hydrogen (LCOH) for each scenario and compares them to current and projected benchmarks. The study also highlights ongoing research projects and technological advancements in the transition from natural gas to H2 in the glass sector. Finally potential barriers to large-scale implementation are discussed along with policy and infrastructure recommendations to foster industrial adoption. These findings suggest that hybrid configurations represent the most promising path toward industrial H2 adoption in glass manufacturing.
Optimized Activation of Coffee-ground Carbons for Hydrogen Storage
Mar 2025
Publication
This study evaluates and compares physical chemical and dual activation methods for preparing activated carbons from spent coffee grounds to optimize their porosity for hydrogen storage. Activation processes including both one-step and two-step chemical and physical methods were investigated incorporating a novel dual activation process that combines chemical and physical activation. The findings indicate that the two-step chemical activation yields superior results producing activated carbons with a high specific surface area of 1680 m2 /g and a micropore volume of 0.616 cm3 /g. These characteristics lead to impressive hydrogen uptake capacities of 2.65 wt% and 3.66 wt% at 77 K under pressures of 1 and 70 bar respectively. The study highlights the potential of spent coffee grounds as a cost-effective precursor for producing high-performance activated carbons.
Trends, Challenges, and Viability in Green Hydrogen Initiatives
Aug 2025
Publication
This review explores the current status of green hydrogen integration into energy and industrial ecosystems. By considering notable examples of existing and developing green hydrogen initiatives combined with insights from the relevant scientific literature this paper illustrates the practical implementation of those systems according to their main end use: power and heat generation mobility industry or their combination. Main patterns are highlighted in terms of sectoral applications geographical distribution development scales storage solutions electrolyzer technology grid interaction and financial viability. Open challenges are also addressed including the high production costs an underdeveloped transport and distribution infrastructure the geopolitical aspects and the weak business models with the industrial sector appearing as the most favorable environment where such challenges may first be overcome in the medium term.
Direct-Coupled Improvement of a Solar-Powered Proton Exchange Membrane Electrolyzer by a Reconfigurable Source
Sep 2024
Publication
This paper deals with proton exchange membrane (PEM) electrolyzers directly coupled with a photovoltaic source. It proposes a method to increase the energy delivered to the electrolyzer by reconfiguring the electrical connection of the arrays according to solar radiation. Unlike the design criterion proposed by the literature the suggested approach considers a source obtained by connecting arrays in parallel depending on solar radiation based on a fixed photovoltaic configuration. This method allows for the optimization of the operating point at medium or low solar radiation where the fixed configuration gives poor results. The analysis is performed on a low-power plant (400 W). It is based on a commercial photovoltaic cell whose equivalent model is retrieved from data provided by the manufacturer. An equivalent model of the PEM electrolyzer is also derived. Two comparisons are proposed: the former considers a photovoltaic source designed according to the traditional approach i.e. a fixed configuration; in the latter a DC/DC converter as interface is adopted. The role of the converter is discussed to highlight the pros and cons. The optimal set point of the converter is calculated using an analytical equation that takes into account the electrolyzer model. In the proposed study an increase of 17% 62% and 93% of the delivered energy has been obtained in three characteristic days summer spring/autumn and winter respectively compared to the fixed PV configuration. These results are also better than those achieved using the converter. Results show that the proposed direct coupling technique applied to PEM electrolyzers in low-power plants is a good trade-off between a fixed photovoltaic source configuration and the use of a DC/DC converter.
Alkaline Electrolysis for Green Hydrogen Production: A Novel, Simple Model for Thermo-electrochemical Coupled System Analysis
Dec 2024
Publication
Alkaline water electrolysis (AWE) is the most mature electrochemical technology for hydrogen production from renewable electricity. Thus its mathematical modeling is an important tool to provide new perspectives for the design and optimization of energy storage and decarbonization systems. However current models rely on numerous empirical parameters and neglect variations of temperature and concentration alongside the electrolysis cell which can impact the application and reliability of the simulation results. Thus this study proposes a simple four-parameter semi-empirical model for AWE system analysis which relies on minimal fitting data while providing reliable extrapolation results. In addition the effect of model dimensionality (i.e. 0D 1/2D and 1D) are carefully assessed in the optimization of an AWE system. The results indicate that the proposed model can accurately reproduce literature data from four previous works (R 2 ≥ 0.98) as well as new experimental data. In the system optimization the trade-offs existing in the lye cooling sizing highlight that maintaining a low temperature difference in AWE stacks (76-80°C) leads to higher efficiencies and lower hydrogen costs.
Hydrogen in Burners: Economic and Environmental Implications
Nov 2024
Publication
For centuries fossil fuels have been the primary energy source but their unchecked use has led to significant environmental and economic challenges that now shape the global energy landscape. The combustion of these fuels releases greenhouse gases which are critical contributors to the acceleration of climate change resulting in severe consequences for both the environment and human health. Therefore this article examines the potential of hydrogen as a sustainable alternative energy source capable of mitigating these climate impacts. It explores the properties of hydrogen with particular emphasis on its application in industrial burners and furnaces underscoring its clean combustion and high energy density in comparison to fossil fuels and also examines hydrogen production through thermochemical and electrochemical methods covering green gray blue and turquoise pathways. It discusses storage and transportation challenges highlighting methods like compression liquefaction chemical carriers (e.g. ammonia) and transport via pipelines and vehicles. Hydrogen combustion mechanisms and optimized burner and furnace designs are explored along with the environmental benefits of lower emissions contrasted with economic concerns like production and infrastructure costs. Additionally industrial and energy applications safety concerns and the challenges of large-scale adoption are addressed presenting hydrogen as a promising yet complex alternative to fossil fuels.
Green Hydrogen Techno-economic Assessments from Simulated and Measured Solar Photovoltaic Power Profiles
Nov 2024
Publication
Studies estimating the production cost of hydrogen-based fuels known as e-fuels often use renewable power profile time series obtained from open-source simulation tools that rely on meteorological reanalysis and satellite data such as Renewables.ninja or PVGIS. These simulated time series contain errors compared to real on-site measured data which are reflected in e-fuels cost estimates plant design and operational performance increasing the risk of inaccurate plant design and business models. Focusing on solar-powered e-fuels this study aims to quantify these errors using high-quality on-site power production data. A state-of-the-art optimization techno-economic model was used to estimate e-fuel production costs by utilizing either simulated or high-quality measured PV power profiles across four sites with different climates. The results indicate that in cloudy climates relying on simulated data instead of measured data can lead to an underestimation of the fuel production costs by 36 % for a hydrogen user requiring a constant supply considering an original error of 1.2 % in the annual average capacity factor. The cost underestimation can reach 25 % for a hydrogen user operating between 40 % and 100 % load and 17.5 % for a fully flexible user. For comparison cost differences around 20 % could also result from increasing the electrolyser or PV plant costs by around 55 % which highlights the importance of using high-quality renewable power profiles. To support this an open-source collaborative repository was developed to facilitate the sharing of measured renewable power profiles and provide tools for both time series analysis and green hydrogen techno-economic assessments.
Experimental Investigation on the Optimal Injection and Combustion Phasing for a Direct Injection Hydrogen-fuelled Internal Combustion Engine for Heavy-duty Applications
Dec 2024
Publication
In the current context of increasing demand for clean transportation hydrogen usage in internal combustion engines (ICEs) represents a viable solution to abate all engine-out criteria pollutants and almost zeroing CO2 tailpipe emissions. Indeed the wider flammability limits thanks to the higher flame propagation speed and the lower minimum ignition energy compared with conventional fuels extend the stable combustion regime to leaner mixtures thus allowing high thermal efficiency keeping under control the NOX emissions. To fully exploit the potential of hydrogen as a fuel and to avoid undesired abnormal combustion processes a deep characterization of the combustion process is needed. With this aim a 6-cylinder 12.9-L heavy-duty engine was converted from a port-fuel injected compressed natural gas to a direct injected hydrogen spark ignition one. A wide experimental campaign was carried out consisting of several sweeps of relative air-fuel ratios spark advances and injection timings at different engine speeds and loads aiming to define a preliminary engine map. The effect of each calibration parameter at different engine load and speed has been analyzed through the combination of relevant combustion parameters as well as NOX emissions. The results have demonstrated the critical influence of the mixture inhomogeneity when the injection is retarded through the top dead center firing as indicated by the increase in NOX emissions and combustion variability. The analysis of the combustion timing has indicated the dependence of the optimal MFB50 on the relative air-fuel ratio. Lastly the analysis of 200 consecutive cycles for each operating condition has allowed the evaluation of the influence of the main calibration parameters on the cyclic variability thus providing further insights about the lean limit of hydrogen in ICE.
Computational Fluid Dynamic (CFD) Analysis of a Cold-adsorbed Hydrogen Tank During Refilling
Sep 2023
Publication
Hydrogen has the potential to be an important source of clean energy but the development of efficient and cost-effective methods for storing hydrogen is a key challenge that needs to be addressed in order to make widespread use of hydrogen as a possible energy sourc. There are different methods for storing hydrogen (i.e. compressed it at high pressures liquefied by cooling the hydrogen to a temperature of -253°C and stored with a chemical compound) each with its own advantages and disadvantages.<br/>MAST3RBoost (Maturing the Production Standards of Ultraporous Structures for High Density Hydrogen Storage Bank Operating on Swinging Temperatures and Low Compression) is a European project which aims to provide a solid benchmark of cold-adsorbed H2 storage (CAH2) at low compression (100 bar or below) by maturation of a new generation of ultraporous materials for mobility applications i.e. H2-powered vehicles including road and railway air-borne and waterborne transportation. Based on a new generation of Machine Learning-improved ultraporous materials – such as Activated Carbons (ACs) and high-density MOFs (Metal-organic Frameworks) – MAST3RBoost project will enable a disruptive path to meet the industry goals by developing the first worldwide adsorption-based demonstrator at the kg-scale.<br/>The design of the tank is supported by numerical investigation by mean of the use of Computational Fluid Dynamic (CFD) commercial code. In this a paper a preliminary analysis of the refilling of tank is presented focused on the effect of different tank configurations on the hydrogen temperature and on the hydrogen adsorption.
European Hydrogen Train the Trainer Programme for Responders: The Impact of HyResponder on Training Across Europe
Jan 2025
Publication
Síle Brennan,
Christian Brauner,
Dennis Davis,
Natalie DeBacker,
Alexander Dyck,
César García Hernández,
André Vagner Gaathaug,
Petr Kupka,
Laurence Grand-Clement,
Etienne Havret,
Deborah Houssin-Agbomson,
Laurent Lecomte,
Eric Maranne,
Pippa Steele,
Paola Russo,
Adolfo Pinilla,
Gerhard Schoepf,
Tom Van Esbroeck and
Vladimir V. Molkov
The impact of the HyResponder project on the training of responders in 10 European countries is described. An overview is presented of training activities undertaken within the project in Austria Belgium Czech Republic France Germany Italy Norway Spain Switzerland and the United Kingdom. National leads with training expertise are given and the longer-term plans in each region are mentioned. Responders from each region took part in a specially tailored “train the trainer” programme and then delivered training within their regions. A flexible approach to training within the HyResponder network has enabled fit for purpose region appropriate activities to be delivered impacting over 1250 individuals during the project and many more beyond. Teaching and learning materials in hydrogen safety for responders have been made available in 8 languages: English Czech Dutch French German Italian Norwegian Spanish. They are being used to inform training within each of the partner countries. Dedicated national working groups focused on hydrogen safety training for responders have been established in Belgium the Czech Republic Italy and Switzerland.
An Up-to-date Perspective of Levelized Cost of Hydrogen for PV-based Grid-connected Power-to-hydrogen Plants Across all Italy
Nov 2024
Publication
Green hydrogen holds potential for decarbonizing the energy sector but high production costs are a major barrier. This study provides a comprehensive techno-economic-financial-environmental analysis of PV-based grid-connected hydrogen production plants targeting hard-to-abate industries having constant hydrogen demand across all Italy. Using real hourly data the Multi Energy System Simulator (MESS) an in-house developed rule-based tool was employed and integrated with Genetic Algorithm for optimal plant sizing. The aim is to minimize the Levelized Cost of Hydrogen (LCOH) while complying with regulatory frameworks for green hydrogen incentives access. Key findings show that hydrogen storage is more advantageous than battery storage for supply-side flexibility and the optimal PV-to-electrolyzer size ratio ranges from 1.8 in Southern Italy to 2.1 in Northern Italy with hydrogen tank designed for daily storage. Considering photovoltaic electrolyzer and battery aging models grid dependence increases by 60 % when comparing the first and worst year of operation and leads to a 7 % increase in LCOH. Transitioning from the strictest (hourly) to the least stringent (annual) temporal correlation increases certified green hydrogen by 22 % while LCOH decreases by only 3 % suggesting that the environmental benefits of stringent temporal requirements outweigh their moderate economic drawbacks. These findings underscore the need for additional national-level incentives to allow the deployment of this technology and achieving cost parity with grey hydrogen.
PyPSA-Earth Sector-coupled: A Global Open-source Multi-energy System Model Showcased for Hydrogen Applications in Countries of the Global South
Jan 2025
Publication
This study presents sector-coupled PyPSA-Earth: a novel global open-source energy system optimization model that incorporates major demand sectors and energy carriers in high spatial and temporal resolution to enable energy transition studies worldwide. The model includes a workflow that automatically downloads and processes the necessary demand supply and transmission data to co-optimize investment and operation of energy systems of countries or regions of Earth. The workflow provides the user with tools to forecast future demand scenarios and allows for custom user-defined data in several aspects. Sector-coupled PyPSA-Earth introduces novelty by offering users a comprehensive methodology to generate readily available sector-coupled data and model of any region worldwide starting from raw and open data sources. The model provides flexibility in terms of spatial and temporal detail allowing the user to tailor it to their specific needs. The capabilities of the model are demonstrated through two showcases for Egypt and Brazil. The Egypt case quantifies the relevant role of PV exceeding 35 GW and electrolysis in Suez and Damietta regions for meeting 16% of the EU hydrogen demand. Complementarily the Brazil case confirms the model’s ability in handling hydrogen planning infrastructure including repurposing of existing gas networks which results in 146 M€ lower costs than building new pipelines. The results prove the suitability of sector-coupled PyPSA-Earth to meet the needs of policymakers developers and scholars in advancing the energy transition. The authors invite the interested individuals and institutions to collaborate in the future developments of the model within PyPSA meets Earth initiative.
A Techno-economic Analysis of Hydrogen Refuelling and Electric Fast-charging Stations: Effects on Cost-competitiveness of Zero-emission Trucks
Jun 2025
Publication
Hydrogen fuel cell electric trucks and battery electric trucks can significantly contribute to the decarbonisation of the heavy-duty vehicles transport segment. Nonetheless a paucity of hydrogen refuelling and fast-charging stations can represent a hindrance to the development of zero-emission vehicles. This work aims to provide a techno-economic analysis with a view to comparing the costs of hydrogen refuelling and electric charging and evaluating their effects on the total cost of ownership of zero-emission trucks. Thus a comprehensive analysis has been conducted on off-site compressed (CH2) cryo-compressed subcooled hydrogen refuelling stations in conjunction with a fast-charging station. The resulting levelized costs of hydrogen and charging have been incorporated into the total cost of ownership analysis. Thus it has been demonstrated that battery electric trucks are more costeffective than hydrogen-fuel cell electric trucks. The findings of this study indicate that the costs associated with electric charging and hydrogen refuelling are comparable and the economic profitability is contingent upon a number of techno-economic variables. Therefore it is not possible to determine a priori whether one solution is more economically competitive than the other. A mixed infrastructure can represent an opportunity for the transport sector decarbonisation whereby electric-charging and hydrogen-refuelling are not mutually exclusive.
Energy Storage and Management of Offshore Wind-Based Green Hydrogen Production
Feb 2025
Publication
The coupling of offshore wind energy with hydrogen production involves complex energy flow dynamics and management challenges. This study explores the production of hydrogen through a PEM electrolyzer powered by offshore wind farms and Lithium-ion batteries. A digital twin is developed in Python with the aim of supporting the sizing and carrying out a techno-economic analysis. A controller is designed to manage energy flows on an hourly basis. Three scenarios are analyzed by fixing the electrolyzer capacity to meet a steel plant’s hydrogen demand while exploring different wind farm configurations where the electrolyzer capacity represents 40% 60% and 80% of the wind farm. The layout is optimized to account for the turbine wake. Results reveal that when the electrolyzer capacity is 80% of the wind farm a better energy balance is achieved with 87.5% of the wind production consumed by the electrolyzer. In all scenarios the energy stored is less than 5% highlighting its limitation as a storage solution in this application. LCOE and LCOH differ minimally between scenarios. Saved emissions from wind power reach 268 ktonCO2 /year while those from hydrogen production amount to 520 ktonCO2 /year underlying the importance of hydrogen in hard-to-abate sectors.
Green Hydrogen as a Sustainable Operations Strategy: A Socio-economic Perspective
Nov 2024
Publication
Hydrogen is an energy carrier that can support the development of sustainable and flexible energy systems. However decarbonization can occur when green sources are used for energy production and appropriate water use is manifested. This work aims to propose a socio-economic analysis of hydrogen production from an integrated wind and electrolysis plant in southern Italy. The estimated production amounts to about 1.8 million kg and the LCOH is calculated to be 3.60 €/kg in the base scenario. Analyses of the alternative scenarios allow us to observe that with a high probability the value ranges between 3.20-4.00 €/kg and that the capacity factor is the factor that most affects the economic results. Social analysis conducted through an online survey shows a strong knowledge gap as only 27.5% claim to know the difference between green and grey hydrogen. There is a slight propensity to install systems near their homes but this tends to increase due to increased knowledge on the topic. Respondents state sustainable behaviours and this study suggests that these aspects should also be transformed into the energy choices that are implemented every day. The study suggests information to policy-makers businesses and citizens as it outlines that green hydrogen is an operations strategy that moves toward sustainable development.
A Novel Hydrogen Leak Detection Method for PEM Fuel Cells Using Active Thermography
Feb 2025
Publication
Hydrogen leakage in Proton Exchange Membrane (PEM) fuel cells poses critical safety efficiency and operational reliability risks. This study introduces an innovative infrared (IR) thermography-based methodology for detecting and quantifying hydrogen leaks towards the outside of PEM fuel cells. The proposed method leverages the catalytic properties of a membrane electrode assembly (MEA) as an active thermal tracer facilitating real-time visualisation and assessment of hydrogen leaks. Experimental tests were conducted on a single-cell PEM fuel cell equipped with intact and defective gaskets to evaluate the method’s effectiveness. Results indicate that the active tracer generates distinct thermal signatures proportional to the leakage rate overcoming the limitations of hydrogen’s low IR emissivity. Comparative analysis with passive tracers and baseline configurations highlights the active tracer-based approach’s superior positional accuracy and sensitivity. Additionally the method aligns detected thermal anomalies with defect locations validated through pressure distribution maps. This novel non-invasive technique offers precise reliable and scalable solutions for hydrogen leak detection making it suitable for dynamic operational environments and industrial applications. The findings significantly advance hydrogen’s safety diagnostics supporting the broader adoption of hydrogen-based energy systems.
Safety Aspects Related to the Underground Hydrogen Storage
Sep 2023
Publication
The transition from fossil fuels to the renewable energies (wind solar) is a key factor to face climate change and build a sustainable reliable and secure energy system. To balance the intermittent energy demand and supply affecting the renewable sources the surplus of electrical energy may be converted in hydrogen and then storage in geological formations. While the risks associated to the natural gas storage in the sub-surface are well known from decades those associated with hydrogen underground storage (UHS) are relatively underexplored. This paper presents an inventory of risks related to large H2-storage in depleted gas and oil fields salt caverns and aquifers. Different issues such as integrity and durability of materials H2 leakages and interaction with the reservoir H2 uncontrolled outflow from the wellhead with potential combustion of air-hydrogen mixture (fire and explosion) soil subsidence and induced seismicity are analyzed.
Environmental Implications and Levelized Cost Analysis of E-fuel Production under Photovoltaic Energy, Direct Air Capture, and Hydrogen
Jan 2024
Publication
The ecological transition in the transport sector is a major challenge to tackle environmental pollution and European legislation will mandate zero-emission new cars from 2035. To reduce the impact of petrol and diesel vehicles much emphasis is being placed on the potential use of synthetic fuels including electrofuels (e-fuels). This research aims to examine a levelised cost (LCO) analysis of e-fuel production where the energy source is renewable. The energy used in the process is expected to come from a photovoltaic plant and the other steps required to produce e-fuel: direct air capture electrolysis and Fischer-Tropsch process. The results showed that the LCOe-fuel in the baseline scenario is around 3.1 €/l and this value is mainly influenced by the energy production component followed by the hydrogen one. Sensitivity scenario and risk analyses are also conducted to evaluate alternative scenarios and it emerges that in 84% of the cases LCOe-fuel ranges between 2.8 €/l and 3.4 €/l. The findings show that the current cost is not competitive with fossil fuels yet the development of e-fuels supports environmental protection. The concept of pragmatic sustainability incentive policies technology development industrial symbiosis economies of scale and learning economies can reduce this cost by supporting the decarbonisation of the transport sector.
Optimal Sizing of Renewables-to-hydrogen Systems in a Suitable-site-selection Geospatial Framework: The Case Study if Italy and Portugal
Jun 2024
Publication
Growing renewable energy deployment worldwide has sparked a shift in the energy landscape with far-reaching geopolitical ramifications. Hydrogen’s role as an energy carrier is central to this change facilitating global trade and the decarbonisation of hard-to-abate sectors. This analysis offers a new method for optimally sizing solar/wind-to-hydrogen systems in specifically suitable locations. These locations are limited to the onshore and offshore regions of selected countries as determined by a bespoke geospatial analysis developed to be location-agnostic. Furthermore the research focuses on determining the best configurations for such systems that minimise the cost of producing hydrogen with the optimisation algorithm expanding from the detailed computation of the classic levelised cost of hydrogen. One of the study’s main conclusions is that the best hybrid configurations obtained provide up to 70% cost savings in some areas. Such findings represent unprecedented achievements for Italy and Portugal and can be a valuable asset for economic studies of this kind carried out by local and national governments across the globe. These results validate the optimisation model’s initial premise significantly improving the credibility of this work by constructively challenging the standard way of assessing large-scale green hydrogen projects.
Local Energy Community to Support Hydrogen Production and Network Flexibility
Jul 2024
Publication
This paper deals with the optimal scheduling of the resources of a renewable energy community whose coordination is aimed at providing flexibility services to the electrical distribution network. The available resources are renewable generation units battery energy storage systems dispatchable loads and power-to-hydrogen systems. The main purposes behind the proposed strategy are enhancement of self-consumption and hydrogen production from local resources and the maximization of the economic benefits derived from both the selling of hydrogen and the subsidies given to the community for the shared energy. The proposed approach is formulated as an economic problem accounting for the perspectives of both community members and the distribution system operator. In more detail a mixed-integer constrained non-linear optimization problem is formulated. Technical constraints related to the resources and the power flows in the electrical grid are considered. Numerical applications allow for verifying the effectiveness of the procedure. The results show that it is possible to increase self-consumption and the production of green hydrogen while providing flexibility services through the exploitation of community resources in terms of active and reactive power support. More specifically the application of the proposed strategy to different case studies showed that daily revenues of up to EUR 1000 for each MW of renewable energy generation installed can be obtained. This value includes the benefit obtained thanks to the provision of flexibility services which contribute about 58% of the total.
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