Italy
Modelling Large-scale Hydrogen Uptake in the Mexican Refinery and Power Sectors
Sep 2023
Publication
Due to the emissions reduction commitments that Mexico compromised in the Paris Agreement several clean fuel and renewable energy technologies need to penetrate the market to accomplish the environmental goals. Therefore there is a need to develop achievable and realistic policies for such technologies to ease the decision-making on national energy strategies. Several countries are starting to develop large-scale green hydrogen production projects to reduce the carbon footprint of the multiple sectors within the country. The conversion sectors namely power and refinery are fundamental sectors to decarbonise due to their energy supply role. Nowadays the highest energy consumables of the country are hydrocarbons (more than 90%) causing a particular challenge for deep decarbonisation. The purpose of this study is to use a multi-regional energy system model of Mexico to analyse a decarbonisation scenario in line with the latest National Energy System Development Program. Results show that if the country wants to succeed in reducing 22% of its GHG emissions and 51% of its short-lived climate pollutants emissions green hydrogen could play a role in power generation in regions with higher energy demand growth rates. These results show regarding the power sector that H2 could represent 13.8 GW or 5.1% of the total installed capacity by 2050 while for the refinery sector H2 could reach a capacity of 157 PJ/y which is around 31.8% of the total share and it is mainly driven by the increasing demands of the transport industry and power sectors. Nevertheless as oil would still represent the largest energy commodity CCS technologies would have to be deployed for new and retrofitted refinery facilities.
Gas Turbine Combustion Technologies for Hydrogen Blends
Sep 2023
Publication
The article reviews gas turbine combustion technologies focusing on their current ability to operate with hydrogen enriched natural gas up to 100% H2. The aim is to provide a picture of the most promising fuel-flexible and clean combustion technologies the object of current research and development. The use of hydrogen in the gas turbine power generation sector is initially motivated highlighting both its decarbonisation and electric grid stability objectives; moreover the state-of-the-art of hydrogen-blend gas turbines and their 2024 and 2030 targets are reported in terms of some key performance indicators. Then the changes in combustion characteristics due to the hydrogen enrichment of natural gas blends are briefly described from their enhanced reactivity to their pollutant emissions. Finally gas turbine combustion strategies both already commercially available (mostly based on aerodynamic flame stabilisation self-ignition and staging) or still under development (like the micro-mixing and the exhaust gas recirculation concepts) are described.
Performance Analysis of a Diabatic Compressed Air Energy Storage System Fueled with Green Hydrogen
Oct 2023
Publication
The integration of an increasing share of Renewable Energy Sources (RES) requires the availability of suitable energy storage systems to improve the grid flexibility and Compressed Air Energy Storage (CAES) systems could be a promising option. In this study a CO2 -free Diabatic CAES system is proposed and analyzed. The plant configuration is derived from a down-scaled version of the McIntosh Diabatic CAES plant where the natural gas is replaced with green hydrogen produced on site by a Proton Exchange Membrane electrolyzer powered by a photovoltaic power plant. In this study the components of the hydrogen production system are sized to maximize the self-consumption share of PV energy generation and the effect of the design parameters on the H2 -CAES plant performance are analyzed on a yearly basis. Moreover a comparison between the use of natural gas and hydrogen in terms of energy consumption and CO2 emissions is discussed. The results show that the proposed hydrogen fueled CAES can effectively match the generation profile and the yearly production of the natural gas fueled plant by using all the PV energy production while producing zero CO2 emissions.
Hydrogen Combustion: Features and Barriers to Its Exploitation in the Energy Transition
Oct 2023
Publication
The aim of this article is to review hydrogen combustion applications within the energy transition framework. Hydrogen blends are also included from the well-known hydrogen enriched natural gas (HENG) to the hydrogen and ammonia blends whose chemical kinetics is still not clearly defined. Hydrogen and hydrogen blends combustion characteristics will be firstly summarized in terms of standard properties like the laminar flame speed and the adiabatic flame temperature but also evidencing the critical role of hydrogen preferential diffusion in burning rate enhancement and the drastic reduction in radiative emission with respect to natural gas flames. Then combustion applications in both thermo-electric power generation (based on internal combustion engines i.e. gas turbines and piston engines) and hard-to-abate industry (requiring high-temperature kilns and furnaces) sectors will be considered highlighting the main issues due to hydrogen addition related to safety pollutant emissions and potentially negative effects on industrial products (e.g. glass cement and ceramic).
LCA of a Proton Exchange Membrane Fuel Cell Electric Vehicle Considering Different Power System Architectures
Sep 2023
Publication
Fuel cell electric vehicles are a promising solution for reducing the environmental impacts of the automotive sector; however there are still some key points to address in finding the most efficient and less impactful implementation of this technology. In this work three electrical architectures of fuel cell electric vehicles were modeled and compared in terms of the environmental impacts of their manufacturing and use phases. The three architectures differ in terms of the number and position of the DC/DC converters connecting the battery and the fuel cell to the electric motor. The life cycle assessment methodology was employed to compute and compare the impacts of the three vehicles. A model of the production of the main components of vehicles and fuel cell stacks as well as of the production of hydrogen fuel was constructed and the impacts were calculated using the program SimaPro. Eleven impact categories were considered when adopting the ReCiPe 2016 midpoint method and the EF (adapted) method was exploited for a final comparison. The results highlighted the importance of the converters and their influence on fuel consumption which was identified as the main factor in the comparison of the environmental impacts of the vehicle.
Energy Performance Assessment of a Solar-driven Thermochemical Cycle Device for Green Hydrogen Production
Sep 2023
Publication
This paper presents a novel dynamic simulation model for assessing the energy performance of solar-driven systems employed in green hydrogen production. The system consists of a parabolic dish collector that focuses solar radiation on two cerium-based thermochemical reactors. The model is based on a transient finitedifference method to simulate the thermal behaviour of the system and it integrates a theoretical analysis of materials and operating principles. Different empirical data were considered for experimentally validating it: a good agreement between experimental and simulated results was obtained for the temperatures calculated inside the thermochemical reactor (R2 = 0.99 MAPE = 6.3%) and the hourly flow rates of hydrogen oxygen and carbon monoxide (R2 = 0.96 MAPE = 10%) inside the thermochemical reactor. The model was implemented in a MatLab tool for the system dynamic analysis under different boundary conditions. Subsequently to explore the capability of this approach the developed tool was used for analysing the examined device operating in twelve different weather zones. The obtained results comprise heat maps of specific crucial instants and hourly dynamic trends showing redox reaction cycles occurring into the thermochemical reactors. The yearly hydrogen production ranges from 1.19 m3 /y to 1.64 m3 /y according to the hourly incident solar radiations outdoor air temperatures and wind speeds. New graphic tools for rapid feasibility studies are presented. The developed tools and the obtained results can be useful to the basic design of this technology and for the multi-objective optimization of its layout and main design/operating parameters.
A Holistic Framework for the Optimal Design and Operation of Electricity, Heating, Cooling and Hydrogen Technologies in Buildings
Jun 2024
Publication
In this work the Design and Operation of Integrated Technologies (DO-IT) framework is developed a comprehensive tool to support short- and long-term technology investment and operation decisions for integrated energy generation conversion and storage technologies in buildings. The novelty of this framework lies in two key aspects: firstly it integrates essential open-source modelling tools covering energy end uses in buildings technology performance and cost and energy system design optimisation into a unified and easily-reproducible framework. Secondly it introduces a novel optimisation tool with a concise and generic mathematical formulation capable of modelling multi-energy vector systems capturing interdependencies between different energy vectors and technologies. The model formulation which captures both short- and long-term energy storage facilitates the identification of smart design and operation strategies with low computational cost. Different building energy demand and price scenarios are investigated and the economic and energy benefits of using a holistic multi-energy-vector approach are quantified. Technology combinations under consideration include: (i) a photovoltaic-electric heat pump-battery system (ii) a photovoltaic-electric heat pump-battery-hot water cylinder system (iii) a photovoltaic-electrolyser‑hydrogen storage-fuel cell system and (iv) a system with all above technology options. Using a university building as a case study it is shown that the smart integration of electricity heating cooling and hydrogen generation and storage technologies results in a total system cost which is >25% lower than the scenario of only importing grid electricity and using a fuel oil boiler. The battery mitigates intra-day fluctuations in electricity demand and the hot-water cylinder allows for efficiently managing heat demand with a small heat pump. In order to avoid PV curtailment excess PV-generated electricity can also be stored in the form of green hydrogen providing a long-term energy storage solution spanning days weeks or even seasons. Results are useful for end-users investment decision makers and energy policy makers when selecting building-integrated low-carbon technologies and relevant policies.
Dynamic Simulation and Thermoeconomic Analysis of a Power to Gas System
Sep 2023
Publication
Power to gas technology is an innovative solution to promote the use of renewable energy technologies also including e-fuels. This work presents a techno-economic analysis of a novel concept of a renewable power to gas plant. A 2.4 MW solid oxide electrolyzer fed by a 3.1 MW photovoltaic field is coupled with a biomethane production unit to produce synthetic methane by means of a 2.4 MW methanation unit. The hydrogen produced by the electrolyzer is used for the methanation reaction aiming at producing natural gas at net zero carbon emissions. The CO2 is obtained as a byproduct of the membrane separation in a biogas upgrading unit. The methanation unit and the electrolyzer models are developed in MatLab and integrated in TRNSYS to perform a dynamic simulation of all the components and the system as a whole. Dynamic simulation results show a 42% increase in the production of natural gas from renewable energy sources. The thermoeconomic analysis shows a remarkable primary energy saving index of 176% and a total amount of 896 tons of CO2 equivalent emissions saved. As expected the critical point is the economic feasibility since the simple payback is 9 years in case local incentives and subsidies are considered. The parametric analysis on the photovoltaic capacity shows that the simple payback dramatically depends on such design parameter varying from 6 years in the best case scenario to 92 years in the worst case scenario.
Liquefied Hydrogen Value Chain: A Detailed Techno-economic Evaluation for its Application in the Industrial and Mobility Sectors
Oct 2023
Publication
Green hydrogen can be efficiently produced in regions rich in renewable sources far from the European largeproduction sites and delivered to the continent for utilization in the industrial and mobility sectors. In this work the transportation of hydrogen from North Africa to North Italy in its liquefied form is considered. A technoeconomic assessment is performed on its value chain which includes liquefaction storage maritime transport distribution regasification and compression. The calculated transport cost for the industrial application (delivery to a hydrogen valley) ranges from 6.14 to 9.16 €/kg while for the mobility application (delivery to refueling stations) the range is 10.96–17.71 €/kg. In the latter case the most cost-effective configuration involves the distribution of liquefied hydrogen and regasification at the refueling stations. The liquefaction process is the cost driver of the value chain in all the investigated cases suggesting the importance of its optimization to minimize the overall transport cost.
Preliminary Design of a Fuel Cell/Battery Hybrid Powertrain for a Heavy-duty Yard Truck for Port Logistics
Jun 2021
Publication
The maritime transport and the port-logistic industry are key drivers of economic growth although they represent major contributors to climate change. In particular maritime port facilities are typically located near cities or residential areas thus having a significant direct environmental impact in terms of air and water quality as well as noise. The majority of the pollutant emissions in ports comes from cargo ships and from all the related ports activities carried out by road vehicles. Therefore a progressive reduction of the use of fossil fuels as a primary energy source for these vehicles and the promotion of cleaner powertrain alternatives is in order. The present study deals with the design of a new propulsion system for a heavy-duty vehicle for port applications. Specifically this work aims at laying the foundations for the development of a benchmark industrial cargo–handling hydrogen-fueled vehicle to be used in real port operations. To this purpose an on-field measurement campaign has been conducted to analyze the duty cycle of a commercial Diesel-engine yard truck currently used for terminal ports operations. The vehicle dynamics has been numerically modeled and validated against the acquired data and the energy and power requirements for a plug-in fuel cell/battery hybrid powertrain replacing the Diesel powertrain on the same vehicle have been evaluated. Finally a preliminary design of the new powertrain and a rule-based energy management strategy have been proposed and the electric energy and hydrogen consumptions required to achieve the target driving range for roll-on and roll-off operations have been estimated. The results are promising showing that the hybrid electric vehicle is capable of achieving excellent energy performances by means of an efficient use of the fuel cell. An overall amount of roughly 12 kg of hydrogen is estimated to be required to accomplish the most demanding port operation and meet the target of 6 h of continuous operation. Also the vehicle powertrain ensures an adequate all-electric range which is between approximately 1 and 2 h depending on the specific port operation. Potentially the hydrogen-fueled yard truck is expected to lead to several benefits such as local zero emissions powertrain noise elimination reduction of the vehicle maintenance costs improving of the energy management and increasing of operational efficiency.
An Insight into Underground Hydrogen Storage in Italy
Apr 2023
Publication
Hydrogen is a key energy carrier that could play a crucial role in the transition to a low-carbon economy. Hydrogen-related technologies are considered flexible solutions to support the large-scale implementation of intermittent energy supply from renewable sources by using renewable energy to generate green hydrogen during periods of low demand. Therefore a short-term increase in demand for hydrogen as an energy carrier and an increase in hydrogen production are expected to drive demand for large-scale storage facilities to ensure continuous availability. Owing to the large potential available storage space underground hydrogen storage offers a viable solution for the long-term storage of large amounts of energy. This study presents the results of a survey of potential underground hydrogen storage sites in Italy carried out within the H2020 EU Hystories “Hydrogen Storage In European Subsurface” project. The objective of this work was to clarify the feasibility of the implementation of large-scale storage of green hydrogen in depleted hydrocarbon fields and saline aquifers. By analysing publicly available data mainly well stratigraphy and logs we were able to identify onshore and offshore storage sites in Italy. The hydrogen storage capacity in depleted gas fields currently used for natural gas storage was estimated to be around 69.2 TWh.
An On-Board Pure H2 Supply System Based on A Membrane Reactor for A Fuel Cell Vehicle: A Theoretical Study
Jul 2020
Publication
In this novel conceptual fuel cell vehicle (FCV) an on-board CH4 steam reforming (MSR) membrane reformer (MR) is considered to generate pure H2 for supplying a Fuel Cell (FC) system as an alternative to the conventional automobile engines. Two on-board tanks are forecast to store CH4 and water useful for feeding both a combustion chamber (designed to provide the heat required by the system) and a multi tubes Pd-Ag MR useful to generate pure H2 via methane steam reforming (MSR) reaction. The pure H2 stream is hence supplied to the FC. The flue gas stream coming out from the combustion chamber is used to preheat the MR feed stream by two heat exchangers and one evaporator. Then this theoretical work demonstrates by a 1-D model the feasibility of the MR based system in order to generate 5 kg/day of pure H2 required by the FC system for cruising a vehicle for around 500 km. The calculated CH4 and water consumptions were 50 and 70 kg respectively per 1 kg of pure H2. The on-board MR based FCV presents lower CO2 emission rates than a conventional gasoline-powered vehicle also resulting in a more environmentally friendly solution.
Energy Sustainability Analysis (ESA) of Energy-Producing Processes: A Case Study on Distributed H2 Production
Sep 2019
Publication
In the sustainability context the performance of energy-producing technologies using different energy sources needs to be scored and compared. The selective criterion of a higher level of useful energy to feed an ever-increasing demand of energy to satisfy a wide range of endo- and exosomatic human needs seems adequate. In fact surplus energy is able to cover energy services only after compensating for the energy expenses incurred to build and to run the technology itself. This paper proposes an energy sustainability analysis (ESA) methodology based on the internal and external energy use of a given technology considering the entire energy trajectory from energy sources to useful energy. ESA analysis is conducted at two levels: (i) short-term by the use of the energy sustainability index (ESI) which is the first step to establish whether the energy produced is able to cover the direct energy expenses needed to run the technology and (ii) long-term by which all the indirect energy-quotas are considered i.e. all the additional energy requirements of the technology including the energy amortization quota necessary for the replacement of the technology at the end of its operative life. The long-term level of analysis is conducted by the evaluation of two indicators: the energy return per unit of energy invested (EROI) over the operative life and the energy payback-time (EPT) as the minimum lapse at which all energy expenditures for the production of materials and their construction can be repaid to society. The ESA methodology has been applied to the case study of H2 production at small-scale (10–15 kWH2) comparing three different technologies: (i) steam-methane reforming (SMR) (ii) solar-powered water electrolysis (SPWE) and (iii) two-stage anaerobic digestion (TSAD) in order to score the technologies from an energy sustainability perspective.
A New Generation of Hydrogen-Fueled Hybrid Propulsion Systems for the Urban Mobility of the Future
Dec 2023
Publication
The H2-ICE project aims at developing through numerical simulation a new generation of hybrid powertrains featuring a hydrogen-fueled Internal Combustion Engine (ICE) suitable for 12 m urban buses in order to provide a reliable and cost-effective solution for the abatement of both CO2 and criteria pollutant emissions. The full exploitation of the potential of such a traction system requires a substantial enhancement of the state of the art since several issues have to be addressed. In particular the choice of a more suitable fuel injection system and the control of the combustion process are extremely challenging. Firstly a high-fidelity 3D-CFD model will be exploited to analyze the in-cylinder H2 fuel injection through supersonic flows. Then after the optimization of the injection and combustion process a 1D model of the whole engine system will be built and calibrated allowing the identification of a “sweet spot” in the ultra-lean combustion region characterized by extremely low NOx emissions and at the same time high combustion efficiencies. Moreover to further enhance the engine efficiency well above 40% different Waste Heat Recovery (WHR) systems will be carefully scrutinized including both Organic Rankine Cycle (ORC)-based recovery units as well as electric turbo-compounding. A Selective Catalytic Reduction (SCR) aftertreatment system will be developed to further reduce NOx emissions to near-zero levels. Finally a dedicated torque-based control strategy for the ICE coupled with the Energy Management Systems (EMSs) of the hybrid powertrain both optimized by exploiting Vehicle-To-Everything (V2X) connection allows targeting H2 consumption of 0.1 kg/km. Technologies developed in the H2-ICE project will enhance the know-how necessary to design and build engines and aftertreatment systems for the efficient exploitation of H2 as a fuel as well as for their integration into hybrid powertrains.
Eco-Sustainable Energy Production in Healthcare: Trends and Challenges in Renewable Energy Systems
Oct 2023
Publication
The shift from fossil fuels to renewable energy systems represents a pivotal step toward the realization of a sustainable society. This study aims to analyze representative scientific literature on eco-sustainable energy production in the healthcare sector particularly in hospitals. Given hospitals’ substantial electricity consumption the adoption of renewable energy offers a reliable low-CO2 emission solution. The COVID-19 pandemic has underscored the urgency for energyefficient and environmentally-responsible approaches. This brief review analyzes the development of experimental simulation and optimization projects for sustainable energy production in healthcare facilities. The analysis reveals trends and challenges in renewable energy systems offering valuable insights into the potential of eco-sustainable solutions in the healthcare sector. The findings indicate that hydrogen storage systems are consistently coupled with photovoltaic panels or solar collectors but only 14% of the analyzed studies explore this potential within hospital settings. Hybrid renewable energy systems (HRES) could be used to meet the energy demands of healthcare centers and hospitals. However the integration of HRES in hospitals and medical buildings is understudied.
The Role of Hydrogen in a Decarbonised Future Transport Sector: A Case Study of Mexico
Sep 2023
Publication
In recent years several approaches and pathways have been discussed to decarbonise the transport sector; however any effort to reduce emissions might be complex due to specific socio-economic and technical characteristics of different regions. In Mexico the transport sector is the highest energy consumer representing 38.9% of the national final energy demand with gasoline and diesel representing 90% of the sector´s total fuel consumption. Energy systems models are powerful tools to obtain insights into decarbonisation pathways to understand costs emissions and rate of deployment that could serve for energy policy development. This paper focuses on the modelling of the current Mexican transport system using the MUSE-MX multi-regional model with the aim to project a decarbonisation pathway through two different scenarios. The first approach being business as usual (BAU) which aims to analyse current policies implementation and the second being a goal of net zero carbon emissions by 2050. Under the considered net zero scenario results show potential deployment of hydrogen-based transport technologies especially for subsectors such as lorries (100% H2 by 2050) and freight train (25% H2 by 2050) while cars and buses tend to full electrification by 2050.
Life Cycle Assessments Use in Hydrogen-related Policies: The Case for a Harmonized Methodology Addressing Multifunctionality
May 2024
Publication
Legislation regulating the sustainability requirements for hydrogen technologies relies more and more on life cycle assessments (LCAs). Due to different scopes and development processes different pieces of EU legislation refer to different LCA methodologies with differences in the way multifunctional processes (i.e. co-productions recycling and energy recovery) are treated. These inconsistencies arise because incentive mechanisms are not standardized across sectors even though the end product hydrogen remains the same. The goal of this paper is to compare the life-cycle greenhouse gas (GHG) emissions of hydrogen from four production pathways depending on the multifunctional approach prescribed by the different EU policies (e.g. using substitution or allocation). The study reveals a large variation in the LCA results. For instance the life-cycle GHG emissions of hydrogen co-produced with methanol is found to vary from 1 kg CO2-equivalent/kg H2 (when mass allocation is considered) to 11 kg CO2-equivalent/kg H2 (when economic allocation is used). These inconsistencies could affect the market (e.g. hydrogen from a certain pathway could be considered sustainable or unsustainable depending on the approach) and the environment (e.g. pathways that do not lead to a global emission reduction could be promoted). To mitigate these potential negative effects we urge for harmonized and strict guidelines to assess the life-cycle GHG emissions of hydrogen technologies in an EU policy context. Harmonization should cover international policies too to avoid the same risks when hydrogen will be traded based on its GHG emissions. The appropriate methodological approach for each production pathway should be chosen by policymakers in collaboration with the LCA community and stakeholders from the industry based on the potential market and environmental consequences of such choice.
Experimental Comparison of Hydrogen Refueling with Directly Pressurized vs. Cascade Method
Aug 2023
Publication
This paper presents a comparative analysis of two hydrogen station configurations during the refueling process: the conventional “directly pressurized refueling process” and the innovative “cascade refueling process.” The objective of the cascade process is to refuel vehicles without the need for booster compressors. The experiments were conducted at the Hydrogen Research and Fueling Facility located at California State University Los Angeles. In the cascade refueling process the facility buffer tanks were utilized as high-pressure storage enabling the refueling operation. Three different scenarios were tested: one involving the cascade refueling process and two involving compressor-driven refueling processes. On average each refueling event delivered 1.6 kg of hydrogen. Although the cascade refueling process using the high-pressure buffer tanks did not achieve the pressure target it resulted in a notable improvement in the nozzle outlet temperature trend reducing it by approximately 8 ◦C. Moreover the overall hydrogen chiller load for the two directly pressurized refuelings was 66 Wh/kg and 62 Wh/kg respectively whereas the cascading process only required 55 Wh/kg. This represents a 20% and 12% reduction in energy consumption compared to the scenarios involving booster compressors during fueling. The observed refueling range of 150–350 bar showed that the cascade process consistently required 12–20% less energy for hydrogen chilling. Additionally the nozzle outlet temperature demonstrated an approximate 8 ◦C improvement within this pressure range. These findings indicate that further improvements can be expected in the high-pressure region specifically above 350 bar. This research suggests the potential for significant improvements in the high-pressure range emphasizing the viability of the cascade refueling process as a promising alternative to the direct compression approach.
Proton Exchange Membrane Electrolyzer Modeling for Power Electronics Control: A Short Review
May 2020
Publication
The main purpose of this article is to provide a short review of proton exchange membrane electrolyzer (PEMEL) modeling used for power electronics control. So far three types of PEMEL modeling have been adopted in the literature: resistive load static load (including an equivalent resistance series-connected with a DC voltage generator representing the reversible voltage) and dynamic load (taking into consideration the dynamics both at the anode and the cathode). The modeling of the load is crucial for control purposes since it may have an impact on the performance of the system. This article aims at providing essential information and comparing the different load modeling.
Monitored Data and Social Perceptions Analysis of Battery Electric and Hydrogen Fuelled Buses in Urban and Suburban Areas
Jul 2023
Publication
Electrification of the transportation sector is one of the main drivers in the decarbonization of energy and mobility systems and it is a way to ensure security of energy supply. Public bus fleets can assist in achieving fast reduction of CO2 emissions. This article provides an analysis of a unique real-world dataset to support decision makers in the decarbonization of public fleets and interlink it with the social acceptance of drivers. Data was collected from 21 fuel cell and electric buses. The tank-to-wheel efficiency results of fuel cell electric buses (FCEB) are much lower than that of battery electric buses (BEB) and there is a higher variation in consumption for BEBs compared to FCEBs. Both technologies permit a strong reduction in CO2 emissions compared to conventional buses. There is a high level of acceptance of drivers which are likely to support the transition towards zero-emission buses introduced by the management.
A Short Review on Ni Based Catalysts and Related Engineering Issues for Methane Steam Reforming
Mar 2020
Publication
Hydrogen is an important raw material in chemical industries and the steam reforming of light hydrocarbons (such as methane) is the most used process for its production. In this process the use of a catalyst is mandatory and if compared to precious metal-based catalysts Ni-based catalysts assure an acceptable high activity and a lower cost. The aim of a distributed hydrogen production for example through an on-site type hydrogen station is only reachable if a novel reforming system is developed with some unique properties that are not present in the large-scale reforming system. These properties include among the others (i) daily startup and shutdown (DSS) operation ability (ii) rapid response to load fluctuation (iii) compactness of device and (iv) excellent thermal exchange. In this sense the catalyst has an important role. There is vast amount of information in the literature regarding the performance of catalysts in methane steam reforming. In this short review an overview on the most recent advances in Ni based catalysts for methane steam reforming is given also regarding the use of innovative structured catalysts.
Hydrogen Role in the Valorization of Integrated Steelworks Process Off-gases through Methane and Methanol Syntheses
Jun 2021
Publication
The valorization of integrated steelworks process off-gases as feedstock for synthesizing methane and methanol is in line with European Green Deal challenges. However this target can be generally achieved only through process off-gases enrichment with hydrogen and use of cutting-edge syntheses reactors coupled to advanced control systems. These aspects are addressed in the RFCS project i3 upgrade and the central role of hydrogen was evident from the first stages of the project. First stationary scenario analyses showed that the required hydrogen amount is significant and existing renewable hydrogen production technologies are not ready to satisfy the demand in an economic perspective. The poor availability of low-cost green hydrogen as one of the main barriers for producing methane and methanol from process off-gases is further highlighted in the application of an ad-hoc developed dispatch controller for managing hydrogen intensified syntheses in integrated steelworks. The dispatch controller considers both economic and environmental impacts in the cost function and although significant environmental benefits are obtainable by exploiting process off-gases in the syntheses the current hydrogen costs highly affect the dispatch controller decisions. This underlines the need for big scale green hydrogen production processes and dedicated green markets for hydrogen-intensive industries which would ensure easy access to this fundamental gas paving the way for a C-lean and more sustainable steel production.
Integration of Renewable Hydrogen Production in Steelworks Off-Gases for the Synthesis of Methanol and Methane
May 2021
Publication
The steel industry is among the highest carbon-emitting industrial sectors. Since the steel production process is already exhaustively optimized alternative routes are sought in order to increase carbon efficiency and reduce these emissions. During steel production three main carbon-containing off-gases are generated: blast furnace gas coke oven gas and basic oxygen furnace gas. In the present work the addition of renewable hydrogen by electrolysis to those steelworks off-gases is studied for the production of methane and methanol. Different case scenarios are investigated using AspenPlusTM flowsheet simulations which differ on the end-product the feedstock flowrates and on the production of power. Each case study is evaluated in terms of hydrogen and electrolysis requirements carbon conversion hydrogen consumption and product yields. The findings of this study showed that the electrolysis requirements surpass the energy content of the steelwork’s feedstock. However for the methanol synthesis cases substantial improvements can be achieved if recycling a significant amount of the residual hydrogen.
Renewable Hydrogen Production Processes for the Off-Gas Valorization in Integrated Steelworks through Hydrogen Intensified Methane and Methanol Syntheses
Nov 2020
Publication
Within integrated steelmaking industries significant research efforts are devoted to the efficient use of resources and the reduction of CO2 emissions. Integrated steelworks consume a considerable quantity of raw materials and produce a high amount of by-products such as off-gases currently used for the internal production of heat steam or electricity. These off-gases can be further valorized as feedstock for methane and methanol syntheses but their hydrogen content is often inadequate to reach high conversions in synthesis processes. The addition of hydrogen is fundamental and a suitable hydrogen production process must be selected to obtain advantages in process economy and sustainability. This paper presents a comparative analysis of different hydrogen production processes from renewable energy namely polymer electrolyte membrane electrolysis solid oxide electrolyze cell electrolysis and biomass gasification. Aspen Plus® V11-based models were developed and simulations were conducted for sensitivity analyses to acquire useful information related to the process behavior. Advantages and disadvantages for each considered process were highlighted. In addition the integration of the analyzed hydrogen production methods with methane and methanol syntheses is analyzed through further Aspen Plus®-based simulations. The pros and cons of the different hydrogen production options coupled with methane and methanol syntheses included in steelmaking industries are analyzed
Electricity Supply Configurations for Green Hydrogen Hubs: A European Case Study on Decarbonizing Urban Transport
Aug 2024
Publication
In this study a techno-economic analysis tool for conducting detailed feasibility studies on the deployment of green hydrogen hubs for fuel cell bus fleets is developed. The study evaluates and compares five green hydrogen hub configurations’ operational and economic performance under a typical metropolitan bus fleet refuelling schedule. Each configuration differs based on its electricity sourcing characteristics such as the mix of energy sources capacity sizing financial structure and grid interaction. A detailed comparative analysis of distinct green hydrogen hub configurations for decarbonising a fleet of fuel-cell buses is conducted. Among the key findings is that a hybrid renewable electricity source and hydrogen storage are essential for cost-optimal operation across all configurations. Furthermore bi-directional grid-interactive configurations are the most costefficient and can benefit the electricity grid by flattening the duck curve. Lastly the paper highlights the potential for cost reduction when the fleet refuelling schedule is co-optimized with the green hydrogen hub electricity supply configuration.
The Role of Hydrogen as Enabler of Industrial Port Area Decarbonoization
Nov 2023
Publication
To meet environmental goals while maintaining economic competitiveness worldwide ports have increased the amount of renewable energy production and have focused in optimizing performances and energy efficiency. However carbon-neutral operation of industrial port areas (IPA) is challenging and requires the decarbonization of industrial processes and heavy transport systems. This study proposes a comprehensive review of decarbon ization strategies for IPA with a particular focus on the role that green hydrogen could play when used as renewable energy carrier. Much information on existing and future technologies was also derived from the analysis of 74 projects (existing and planned) in 36 IPAs 80 % of which are in Europe concerning hydrogenbased decarbonization strategies. The overall review shows that engine operation of ships at berth are respon sible of more than 70 % of emissions in ports. Therefore onshore power supply (OPS) seems to be one of the main strategies to reduce port pollution. Nevertheless OPS powered by hydrogen is not today easily achievable. By overcoming the current cost-related and regulation barriers hydrogen can also be used for the import/export of green energy and the decarbonization of hard-to-abate sectors. The technical and economic data regarding hydrogen-based technologies and strategies highlighted in this paper are useful for further research in the field of definition and development of decarbonization strategies in the IPA.
Hydrogen Refueling Station Cost Model Applied to Five Real Case Studies for Fuel Cell buses
Oct 2021
Publication
Hydrogen Refueling Stations (HRS) are a key infrastructure to the successful deployment of hydrogen mobility. Their cost-effectiveness will represent an increasingly crucial issue considering the foreseen growth of vehicle fleets from few captive fleets to large-scale penetration of hydrogen vehicles. In this context a detailed component-oriented cost model is important to assess HRS costs for different design concepts layout schemes and possible customizations respect to aggregate tools which are mostly available in literature. In this work an improved version of a previously developed component-oriented scale-sensitive HRS cost model is applied to 5 different European HRS developed within the 3Emotion project with different refueling capacities (kgH2/day) hydrogen supply schemes (in-situ production or delivery) storage volumes and pressures and operational strategies. The model output allows to assess the upfront investment cost (CAPEX) the annual operational cost (OPEX) and the Levelized Cost of Hydrogen (LCOH) at the dispenser and identify the most crucial cost components. The results for the five analyzed HRS sites show an LCOH at the nozzle of around 8-9 €/kg for delivery based HRSs which are mainly dominated by the H2 retail price and transport service price and around 11-12 €/kg for on-site producing HRS for which the electrolyzer CAPEX and electricity price plays a key role in the cost structure. The compression storage and dispensing sections account for between 1-3 €/kg according to the specific design & performance requirements of the HRS. The total LCOH values are comparable with literature standard market prices for similar scale HRSs and with the 3Emotion project targets.
Is Green Hydrogen an Environmentally and Socially Sound Solution for Decarbonizing Energy Systems Within a Circular Economy Transition?
May 2025
Publication
Green hydrogen (GH2) is expected to play an important role in future energy systems in their fight against climate change. This study after briefly recalling how GH2 is produced and the main steps throughout its life cycle analyses its current development environmental and social impacts and a series of case studies from selected literature showing its main applications as fuel in transportation and electricity sectors as a heat producer in high energy intensive industries and residential and commercial buildings and as an industrial feedstock for the production of other chemical products. The results show that the use of GH2 in the three main areas of application has the potential of contributing to the decarbonization goals although its generation of non-negligible impacts in other environmental categories requires attention. However the integration of circular economy (CE) principles is important for the mitigation of these impacts. In social terms the complexity of the value chain of GH2 generates social impacts well beyond countries where GH2 is produced and used. This aspect makes the GH2 value chain complex and difficult to trace somewhat undermining its renewability claims as well as its expected localness that the CE model is centred around.
Performance and Emissions Evaluation of a Turbofan Burner with Hydrogen Fuel
Mar 2025
Publication
This paper examines the changes in the performance level and pollutant emissions of a combustion chamber for turbofan engines. Two different fuels are compared: a conventional liquid fuel of the JET-A (kerosene) class and a hydrogen-based gaseous fuel. A turbofan engine delivering a 70 kN thrust at cruise conditions and 375 kN thrust at takeoff is considered. The comparison is carried out by investigating the combustion pattern with different boundary conditions the latter assigned along a typical flight mission. The calculations rely on a combined approach with a preliminary lumped parameter estimation of the engine performance and thermodynamic properties under different flight conditions (i.e. take-off climbing and cruise) and a CFD-based combustion simulation employing as boundary conditions the outputs obtained from the 0-D computations. The results are discussed in terms of performance thermal properties distributions throughout the combustor and of pollutant concentration at the combustor outflow. The results demonstrate that replacing the JET-A fuel with hydrogen does not affect the overall engine performance significantly and stable and efficient combustion takes place inside the burner although a different temperature regime is observable causing a relevant increase in thermal NO emissions.
Optimizing Proton Exchange Membrane Electrolyzer Performance Through Dynamic Pressure and Temperature Control: A Mixed-integer Linear Programming Approach
Aug 2025
Publication
Hydrogen is a key energy carrier for decarbonizing multiple sectors particularly when produced via water electrolysis powered by renewable energy. Proton exchange membrane (PEM) electrolyzers are well suited for this application due to their ability to rapidly adjust to fluctuating power inputs. Despite being conventionally operated at high temperatures and pressures to reduce heating and compression needs recent studies suggest that under partial loads lower operating conditions may enhance efficiency. This study introduces a novel optimization framework for dynamically adjusting pressure and temperature in PEM electrolyzers. The model integrates an efficiency map within a Mixed-Integer Linear Programming (MILP) formulation and applies McCormick tightening to address nonlinearities. A one-week case study demonstrates operational cost reductions of up to 12.5 % through optimal control favoring lower temperatures and pressures at low current densities and higher temperatures near rated load while maintaining moderate pressures. The results show improved efficiency and reduced hydrogen crossover enhancing safety and enabling scalable application over extended time horizons. These insights are valuable for long-term planning and evaluation of hydrogen production and storage systems.
Decarbonisation Pathways for the Pulp and Paper Industry: A Comprehensive Review
Jul 2025
Publication
The world is experiencing the effects of climate change at an increasing rate including rising average global temperature caused primarily by greenhouse gas (GHG) emissions. Energy-intensive industries (EIIs) are major contributors to greenhouse gas emissions. The pulp and paper industry (PPI) is among the top five most energyintensive industries and it accounts for approximately 6 % of global industrial energy use and 2 % of direct industrial CO2 emissions. Therefore it is important to decarbonize this industrial sector to achieve the climate policy goal of achieving net-zero emissions as per the Paris Agreement. This paper presents a comprehensive review of the decarbonization options also known as decarbonization pathways for the pulp and paper industrial sector. These pathways are selected from available literature and they mainly include energy efficiency measures (EEMs) paper recycling switching to carbon-neutral fuels such as biomass and hydrogen electrification of heat supply and carbon capture & storage (CCS) among other emerging technologies. After identifying each decarbonization pathway is discussed in detail with its drivers and barriers to implementation. The Analytical Hierarchy Process AHP a multi-criteria decision-making MCDM technique is carried out to rank the decarbonization pathways on five distinct criteria: cost emission reduction potential technological readiness level (TRL) implementation time and scalability. The ranking is carried out in four distinct criteria weight regimes to present clear choices on different criterion weights. This review paper aims to add to the existing literature to provide clear indications in choosing the pathways toward the decarbonization effort in the pulp & paper industry under various strategic priorities.
Dual Pathways for Refinery Off-gas Processing: Comparative Analysis of Steam Reforming and Co-electrolysis
Aug 2025
Publication
In an effort to bridge the gap between academic research and industrial application this study investigates the integration potential of steam methane reforming and Co-electrolysis for the efficient conversion of refinery offgases into high-purity syngas. Experimental work was conducted under conditions representative of industrial environments using platinum- and nickel-based catalysts in steam reforming to assess methane conversion and H2 /CO ratio at varying temperatures and gas hourly space velocities (GHSV). Co-electrolysis was evaluated in solid oxide electrolysis cells (SOECs) across a range of gas compositions (H2O/CO2 /H2 /CO) including pure CO2 electrolysis as a strategy for pre-electrolysis hydrogen removal. Electrochemical performance was analyzed using impedance spectroscopy distribution of relaxation times (DRT) and current–voltage characterization. Results confirm the superior stability and performance of the Pt catalyst under high-throughput conditions while Ni-based systems were more sensitive to operational fluctuations. In the SOEC increased H2O content accelerated reaction kinetics whereas CO2 concentration governed polarization resistance. To enable optimal SOEC operation the addition of steam downstream of the reformer is proposed as a means of adjusting the reformate composition. The findings demonstrate that tuning reforming and electrolysis conditions in tandem offers a promising route for sustainable syngas production using renewable electricity. This work establishes a foundation for further development of integrated thermo-electrochemical systems tailored to industrial gas streams.
Green Hydrogen Production from Biogas or Landfill Gas by Steam Reforming or Dry Reforming: Specific Production and Energy Requirements
May 2025
Publication
Biogas is a crucial renewable energy source for green hydrogen (H2) production reducing greenhouse gas emissions and serving as a carbon-free energy carrier with higher specific energy than traditional fuels. Currently methane reforming dominates H2 production to meet growing global demand with biogas/landfill gas (LFG) reform offering a promising alternative. This study provides a comprehensive simulation-based evaluation of Steam Methane Reforming (SMR) and Dry Methane Reforming (DMR) of biogas/LFG using Aspen Plus. Simulations were conducted under varying operating conditions including steam-to-carbon (S/C) for SMR and steam-to-carbon monoxide (S/CO) ratios for DMR reforming temperatures pressures and LFG compositions to optimize H2 yield and process efficiency. The comparative study showed that SMR attains higher specific H2 yields (0.14–0.19 kgH2/Nm3 ) with specific energy consumption between 0.048 and 0.075 MWh/kg of H2 especially at increased S/C ratios. DMR produces less H2 than SMR (0.104–0.136 kg H2/Nm3 ) and requires higher energy inputs (0.072–0.079 MWh/kg H2) making it less efficient. Both processes require an additional 1.4–2.1 Nm3 of biogas/LFG per Nm3 of feed for energy. These findings provide key insights for improving biogas-based H2 production for sustainable energy with future work focusing on techno–economic and environmental assessments to evaluate its feasibility scalability and industrial application.
Life Cycle Assessments in Hydrogen-based Energy Storage Systems
Aug 2025
Publication
Hydrogen is increasingly recognized as an element in the effort to decarbonize the energy sector. Within the development of large-scale supply chain the storage phase emerges as a significant challenge. This study reviews Life Cycle Assessment (LCA) literature focused exclusively on hydrogen as an energy vector aiming to identify areas for improvement highlight effective solutions and point out research gaps. The goal is to provide a comprehensive overview of hydrogen storage technologies from an environmental perspective. A systematic search was conducted in the SCOPUS database using a specific set of keywords resulting in the identification of 30 relevant studies. These works explore hydrogen storage across different scales and applications which were classified into five categories based on the type of storage application most of them related to stationary use. The majority of the selected studies focus on storing hydrogen in compressed gas tanks. Notably 33 % of the analyzed articles assess only greenhouse gas (GHG) emissions and 10 % evaluate only two environmental impact categories including GHGs. This reflects a limited understanding of broader environmental impacts with a predominant focus on CO₂eq emissions. When comparing different case studies storage methods associated with the lowest emissions include metal hydrides and underground hydrogen storage. Another important observation is the trend of decreasing CO₂eq emissions as the storage system scale increases. Future studies should adopt more comprehensive approaches by analyzing a wider range of hydrogen storage technologies and considering multiple environmental impact categories in LCA. Moreover it is crucial to integrate environmental economic and social dimensions of sustainability as multidimensional assessments are essential to support well-informed balanced decisions that align with the sustainable development of hydrogen storage systems.
Towards Sustainable Energy Independence: A Case Study of Green Hydrogen as Seasonal Storage Integration in a Small Island
Mar 2025
Publication
Tilos a Greek island in the Mediterranean Sea hosts a pioneering hybrid energy system combining an 800-kW wind turbine and a 160-kWp photovoltaic (PV) field. The predominance of wind power makes the energy production of the island almost constant during the year while the consumption peaks in summer in correspondence with the tourist season. If the island wants to achieve complete selfsufficiency seasonal storage becomes compulsory. This study makes use of measured production data over 1 year to understand the best combination of renewable energy generation and storage to match energy production with consumption. A stochastic optimization based on a differential evolution algorithm is carried out to showcase the configuration that minimizes the levelized cost of required energy (LCORE) in different scenarios. System performance is simulated by progressively increasing the size of the storage devices including a combination of Lithium-ion batteries and power-to-gas-topower (P2G2P) technologies and the PV field. An in-depth market review of current and forecasted prices for RES and ESS components supports the economic analysis including three time horizons (current and projections to 2030 and 2050) to account for the expected drop in component prices. Currently the hybrid storage system combining BESS and P2G2P is more cost-effective (264 €/MWh) than a BESS-only system (320 €/MWh). In the mid-term (2030) the expected price drop in batteries will shift the optimal solution towards this technology but the LCORE reached by the hybrid storage (174 €/MWh) will still be more economical than BESS-only (200 €/MWh). In the long term (2050) the expected price drop in hydrogen technologies will push again the economic convenience of P2G2P and further reduce the LCORE (132.4 €/MWh).
Interplay Between Renewable Energy Factor and Levelised Costs in PV-driven Buildings using Hydrogen Fuel Cell System as an Energy Storage Solution
Apr 2025
Publication
This study introduces an effective analysis framework for exploring the complex interrelation between the renewable energy factor (REF) and the economic dimensions of a PV-driven microgrid featuring a dual-level storage system that incorporates both hydrogen and electrical energy storage. By establishing a coupled model that integrates dynamic simulations with a statistical multi-objective optimization algorithm the research aims to achieve optimal component sizing—a critical step in assessing the hybrid system across various REF levels—while effectively reducing the levelized cost of electricity (LCOE). Using the analysis outcomes of a case study a comprehensive techno-economic assessment facilitates a nuanced evaluation of the interplay between the REF system economics across various equipment cost quartiles and grid tariffs addressing the feasibility of the proposed solution for a sustainable energy transition. The results highlight how grid tariffs and REF jointly influence LCOE values across cost quartiles impacting hybrid system design and decision-making. An exponential correlation is observed between life cycle cost (LCC) and REF with the increase in annual operating costs being marginal compared to the initial cost rise. For the net-zero energy case the LCOE ranges from 0.0380 to 0.1873 $/kWh while at REF = 0.6 it spans from 0.0461 to 0.1334 $/kWh reflecting a 71 % larger difference (range). A sensitivity analysis indicates that each 5 % increase in REF leads to an average 20.7 % rise in payback period (PBP) for a given grid tariff.
An Economic and Environmental Assessment of Different Bus Powertrain Technologies in Public Transportation
Dec 2024
Publication
Hydrogen and electric buses are considered effective options for decarbonizing the public transportation sector positioning them as a leader in this transition. This study models the environmental and economic performances of a set of bus powertrain technologies considering a real case-study of suburban public transport in Italy and including fuel cell electric vehicles (FCEV) battery electric vehicles (BEV) biomethane-powered vehicles (CBM) natural gas (CNG) and diesel buses. The environmental performances of FCEV and BEV are significantly influenced by the energy source used for hydrogen production or battery charging. Specifically using the electricity mix for FCEV leads to the highest greenhouse gas emissions and fossil fuel demand. In contrast BEV show better environmental performance than conventional powertrains especially when powered by photovoltaics. When powered by photovoltaics BEV reveal similar results to FCEV in terms of environmental impacts except for resource depletion where both perform poorly. Transitioning from diesel to BEV or FCEV can enhance local air quality regardless of the energy source. The economic analysis indicates that FCEV are the most expensive option followed by BEV both of which are currently costlier than diesel and CNG systems. CBM from waste streams emerges as a cost-effective and environmentally friendly solution. This study suggests prioritizing biomethane derived from biowaste manure and residual biomass (excluding energy crops) as a part of the fuels for public transport decarbonization in the EU to advance EU decarbonization goals despite limitations due to resource availability. Furthermore BEV powered by renewables should be prioritized whenever their range is adequate.
Green Hydrogen Production via Floating Photovoltaic Systems on Irrigation Reservoirs: An Italian Case Study
Apr 2025
Publication
This study investigates the potential for establishing a self-sufficient renewable hydrogen production facility utilising a floating photovoltaic (FPV) system on an artificial irrigation reservoir located in a small municipality in southern Italy. The analysis examines the impact of different system configurations and operating conditions on the technical economic and environmental performance with a particular focus on hydrogen production and water conservation resulting from reduced evaporation. Different sizes of the FPV plant are considered with and without a tracking system. The electrolyser performance is evaluated under both fixed and variable load conditions also considering the integration of battery storage to ensure consistent operation. The findings indicate that the adoption of the largest FPV plant can result in the conservation of approximately 1.87 million m3 of water annually while simultaneously producing up to 4199 tons of hydrogen per year in variable load mode—more than twice the output compared to fixed load conditions. Although battery integration increases hydrogen production it also leads to higher investment and maintenance costs. Therefore the variable load operation emerges as the most economically viable option reducing the levelized cost of hydrogen (LCOH) to €13.18/kg a 26 % reduction compared to fixed load operation. Moreover the implementation of a vertical axis tracking system leads to only marginal LCOH reductions (maximum 2.2 %) and does not justify the additional complexity. In all tested scenarios the system proves to be self-sustaining. Given the case study’s location in southern Italy—where a pilot project for fuel cell–battery hybrid trains is underway—the hydrogen produced is assumed to be used for railway applications as a possible offtaker. The analysis shows that the potential of the system in terms of hydrogen production is much higher (tens of times) than the estimated demand of the present hydrogen railway configuration thus suggesting that a significant expansion of the number of trains and routes served could be considered. Although this work is based on a specific case study its key findings are potentially replicable in other contexts—particularly in Mediterranean or semi-arid regions where water scarcity may otherwise act as a limiting factor for the deployment of hydrogen production systems.
Blue Hydrogen can be Low-Carbon, A Techno-Economic-Environmental Analysis
Oct 2025
Publication
Hydrogen produced through natural gas reforming with carbon capture and storage (blue H2) is expected to supply up to 30 % of global low-carbon hydrogen by 2030. However wide variability in reported findings creates uncertainty about its future role. To address this the present techno-economic-environmental study from a lifecycle perspective evaluates whether blue hydrogen can meet carbon footprint thresholds (3 and 3.4 kg CO2 eq./ kg H2) required to qualify as low-carbon hydrogen. Several configurations of either chemical absorption or lowtemperature CO2 separation techniques integrated with auto-thermal reforming are modeled. Results show that low-temperature separation can achieve comparable or even superior energetic performance to conventional capture methods with cold gas and overall efficiencies reaching up to 80 % and 78 % respectively. The economic analysis estimates the levelized cost of blue hydrogen at 3.5–4 €/kg under 2024 EU average nonhousehold consumer natural gas and electricity prices and 2.4–2.8 €/kg under Italy’s 2024 wholesale prices. From an environmental standpoint life-cycle assessment indicates an average carbon footprint of 2.5 kg CO2 eq./ kg H2 assuming photovoltaic electricity for auxiliary power and excluding more carbon-intensive natural gas supply chains. The findings highlight that partial electrification of the CO2 separation unit use of renewable electricity and maximizing capture rates are key factors essential for producing compliant blue H2. Furthermore adopting ultra-low-emission natural gas supply chains could reduce blue H2′s carbon footprint to the level of green H2 suggesting that the introduction of certificate-of-origin schemes for natural gas can guarantee blue H2 with minimal emissions.
Lessons Learned from HIAD 2.0: Inspection and Maintenance to Avoid Hydrogen-induced Material Failures
Feb 2023
Publication
Hydrogen has the potential to make countries energetically self-sufficient and independent in the long term. Nevertheless its extreme combustion properties and its capability of permeating and embrittling most metallic materials produce significant safety concerns. The Hydrogen Incidents and Accidents Database 2.0 (HIAD 2.0) is a public repository that collects data on hydrogen-related undesired events mainly occurred in chemical and process industry. This study conducts an analysis of the HIAD 2.0 database mining information systematically through a computer science approach known as Business Analytics. Moreover several hydrogen-induced ma terial failures are investigated to understand their root causes. As a result a deficiency in planning effective inspection and maintenance activities is highlighted as the common cause of the most severe accidents. The lessons learned from HIAD 2.0 could help to promote a safety culture to improve the abnormal and normal events management and to stimulate a widespread rollout of hydrogen technologies.
Modelling Thermodiffusive Instabilities in Hydrogen Flames and their Impact on the Combustion Process in a Direct-injection Hydrogen Engine
Sep 2025
Publication
Hydrogen-fueled Internal Combustion Engines (H2-ICEs) are typically operated with lean mixtures to minimize NOx emissions and reduce the risk of abnormal combustion events. Due to hydrogen’s low Lewis number premixed hydrogen-air flames in lean conditions exhibit strong thermodiffusive instabilities which make the numerical simulation of the combustion process particularly challenging. Indeed the intensity of these instabilities is significantly influenced by thermodynamic parameters – such as mixture temperature pressure and dilution rate – resulting in substantial variations in combustion behaviour across different operating conditions. Therefore they have to be properly considered not only to ensure model robustness but also to improve model accuracy over a wider range of operations. In this study the combustion process in a Direct Injection H2-ICE was analyzed using 3D-CFD simulations relying on a flamelet-based combustion model. Two sets of lookup flame speed maps were defined: laminar flame speed (SL) maps derived from standard 1D-CFD simulations in homogeneous reactor and freely propagating flame speed (SM) maps which account for the effects of thermodiffusive instabilities. The model that uses SL maps required the recalibration of some combustion model parameters when changing the dilution rate to ensure consistency with experimental data. Instead the model relying on SM maps featured a noticeable accuracy across different air-to-fuel ratios without the need for recalibration any combustion model parameter highlighting the key role of thermodiffusive flame instabilities on the combustion process. Based on these findings the impact of such instabilities was evaluated throughout the entire combustion process from both global and local perspectives. The relevance of thermodiffusive instabilities was observed to increase with the air-to-fuel ratio thereby enhancing combustion speed in leaner mixtures. Additionally the implementation of thermodiffusive instabilities was found to affect also preferred direction of flame propagation as stronger instabilities were identified in the leanest and low-temperature portions of the flame front. Novelty and significance This study addresses a critical knowledge gap regarding the role of thermodiffusive flame instabilities in accurately replicating the combustion process of a direct-injection internal combustion engine within a RANS simulation framework. Indeed while these instabilities have been shown to significantly enhance the mixture consumption rate in quiescent environments at low to moderate pressures and temperatures particularly in lean mixtures their impact on the burn rate under engine-like conditions has not yet been systematically investigated to the best of the authors’ knowledge. This work provides a comprehensive analysis of the significance of these instabilities in the combustion process of a direct-injection hydrogen internal combustion engine. The analysis is conducted from both a global perspective assessing their overall influence on the combustion process and a local perspective examining how they alter flame front characteristics when incorporated into the model.
New Perspectives on Catalytic Hydrogen Production by the Reforming, Partial Oxidation and Decomposition of Methane and Biogas
Sep 2023
Publication
The article provides a short review on catalyst-based processes for the production of hydrogen starting from methane both of fossil origin and from sustainable processes. The three main paths of steam- and dry-reforming partial oxidation and thermo-catalytic decomposition are briefly introduced and compared above all with reference to the latest publications available and to new catalysts which obey the criteria of lower environmental impact and minimize the content of critical raw materials. The novel strategies based on chemical looping with CO2 utilization membrane separation electrical-assisted (plasma and microwave) processes multistage reactors and catalyst patterning are also illustrated as the most promising perspective for CH4 reforming especially on small and medium scale. Although these strategies should only be considered at a limited level of technological readiness research on these topics including catalyst development and process optimization represents the crucial challenge for the scientific community
Streamlining and Improving Some Aspects of the Governance of the Energy Sector
Sep 2025
Publication
The governance of the EU energy sector has gradually evolved over time to reflect and support the closer integration of the Internal Electricity Market. As the EU energy sector faces new challenges both at the local and cross-border levels its governance might once again need to be reviewed to ensure that it remains fit for the future. This Policy Brief highlights three opportunities for streamlining the governance of the electricity (and gas) sector(s) at the cross-border level related to: (i) the ‘all TSOs’ or ‘all relevant TSOs’ processes; (ii) the regulatory oversight of EU-wide entities; and (iii) the operation of the electricity market coupling. Other areas for improvement in the current governance framework may also emerge and one suggestion relates to the dual role of the ENTSOs both as (i) entities responsible for a number of essential tasks for the energy sector and (ii) associations with TSOs as their members.
In-situ Surface Engineering of Ternary Eco-friendly QDs for Enhanced Photoelectrochemical Hydrogen Production
Oct 2025
Publication
Ternary I-III-VI quantum dots (QDs) have recently received wide attention in solar energy conversion technologies because of their non-toxicity tunable band gap and composition-dependant optical properties. However their complex non-stoichiometry induces high density of surface traps/defects which significantly affects solar energy conversion efficiencies and long-term stability. This work presents an in-situ growth passivation approach to encapsulate ternary Cu:ZnInSe with ZnSeS alloyed shell (CZISe/ZSeS QDs) as light harvesters for solar-driven photoelectrochemical (PEC) hydrogen (H2) production. The engineered CZISe/ZSeS QDs coupled with TiO2- MWCNTs hybrid photoanode exhibit a high photocurrent density of 13.15 mA/cm2 at 0.8 V vs RHE under 1 sun illumination which is 20.5 % higher than bare CZISe QDs/TiO2 photoanode based device. In addition we observed a 48 % enhancement in the long-term stability with ~88 % current retained after 6000 s. These results indicate that the effective shell passivation has mitigated the surface traps/defects leading to suppressed charge recombination and improved charge transfer efficiency as confirmed by optoelectronic carrier dynamics measurements and theoretical simulations. The findings hold great promise on improving the performance of ternary/multinary eco-friendly colloidal QDs by surface engineering for effective utilization in solar energy conversion technologies.
Hydrogen via Co-Electrolysis of Water and CO2: Challenge or Solution for Industrial Decarbonization?
Aug 2025
Publication
The paper investigates the potential of co-electrolysis as a viable pathway for hydrogen production and industrial decarbonization expanding on previous studies on water electrolysis. The analysis adopts a general and critical perspective aiming to assess the realistic scope of this technology with regard to current energy and environmental needs. Although co-electrolysis theoretically offers improved efficiency by simultaneously converting H2O and CO2 into syngas the practical advantages are difficult to consolidate. The study highlights that the energetic margins of the process remain relatively narrow and that several key aspects including system irreversibility and the limited availability of CO2 in many contexts significantly constrain its applicability. Despite the growing interest and promising technological developments co-electrolysis still faces substantial challenges before it can be implemented on a larger scale. The findings suggest that its success will depend on targeted integration strategies advanced thermal management and favorable boundary conditions rather than on the intrinsic efficiency of the process alone. However there are specific sectors where assessing the implementation potential of co-electrolysis could be of interest a perspective this paper aims to explore.
The Impact of Temporal Hydrogen Regulation on Hydrogen Exporters and their Domestic Energy Transition
Aug 2025
Publication
As global demand for green hydrogen rises potential hydrogen exporters move into the spotlight. While exports can bring countries revenue large-scale on-grid hydrogen electrolysis for export can profoundly impact domestic energy prices and energy-related emissions. Our investigation explores the interplay of hydrogen exports domestic energy transition and temporal hydrogen regulation employing a sector-coupled energy model in Morocco. We find substantial co-benefits of domestic carbon dioxide mitigation and hydrogen exports whereby exports can reduce market-based costs for domestic electricity consumers while mitigation reduces costs for hydrogen exporters. However increasing hydrogen exports in a fossil-dominated system can substantially raise market-based costs for domestic electricity consumers but surprisingly temporal matching of hydrogen production can lower these costs by up to 31% with minimal impact on exporters. Here we show that this policy instrument can steer the welfare (re-)distribution between hydrogen exporting firms hydrogen importers and domestic electricity consumers and hereby increases acceptance among actors.
On the Relationship Between Pressure Collapse Rate and Nusselt Number During Sloshing in Cryogenic Liquid Hydrogen Tanks
Oct 2025
Publication
Pressure collapse in sloshing cryogenic liquid hydrogen tanks is a challenge for existing models which often diverge from experimental data. This paper presents a novel lumped-parameter model that overcomes these limitations. Based on a control volume analysis our approach simplifies the complex non-equilibrium physics into a single dimensionless ordinary differential equation governing the liquid’s temperature. We demonstrate this evolution is controlled by one key parameter: the interfacial Nusselt number (). A method for estimating directly from pressure data is also provided. Validated against literature data the model predicts final tank temperatures with deviation of 0.88K (<5% relative error) from measurements thereby explaining the associated pressure collapse. Furthermore our analysis reveals that the Nusselt number varies significantly during a single sloshing event—with calculated values ranging from a peak of 5.81 × 105 down to 7.58 × 103—reflecting the transient nature of the phenomenon.
Photocatalytic Generation of Hydrogen from a Non-carbon Source, Ammonia in Aqueous Solutions
Aug 2025
Publication
This review investigates hydrogen production via photocatalysis using ammonia a carbon-free source potentially present in wastewater. Photocatalysis offers low energy requirements and high conversion efficiency compared to electrocatalysis thermocatalysis and plasma catalysis. However challenges such as complex material synthesis low stability spectral inefficiency high costs and integration barriers hinder industrial scalability. The review addresses thermodynamic requirements reaction mechanisms and the role of pH in optimizing photocatalysis. By leveraging ammonia’s potential and advancing photocatalyst development this study provides a framework for scalable sustainable hydrogen production and simultaneous ammonia decomposition paving the way for innovative energy solutions and wastewater management.
Hydrogen Blending in Gas Pipelines: Fluid-dynamic Insights, Risks, and Recommendations
Mar 2025
Publication
Massive theoretical and applied research is underway worldwide to assess the viability of transporting natural gas-hydrogen blends in pipelines. For the first time this work derives simplified but closed-form equations that describe how changes in gas properties due to hydrogen blending at different volumes map to specific changes in pressure drop compressor power and linepack. These first-of-their-kind equations which are extensively validated against transient gas flow models enabled three unprecedented and unique findings. The first finding which quantifies how a change in demand maps to a change in delay and swing on the supply side reveals that pressure swings increase monotonically with an increase in hydrogen blending volume translating into an increase in pipeline fatigue and risk of failure. The second finding crucially shows that pressure drop does not monotonically increase with an increase in hydrogen blending volume; in fact it is highest at around 85 % hydrogen volume not at 100 %. The third finding shows that the decrease in linepack as a result of an increase in hydrogen volume is not only related to the gross calorific value of the gas mixture but also to the pressure-tocompressibility factor ratio suggesting that smaller parallel pipelines can offset this linepack reduction compared to a single larger pipeline.
Life Cycle Assessment of Different Powertrain Alternatives for a Clean Urban Bus Across Diverse Weather Conditions
Aug 2025
Publication
At present the decarbonization of the public transport sector plays a key role in international and regional policies. Among the various energy vectors being considered for future clean bus fleets green hydrogen and electricity are gaining significant attention thanks to their minimal carbon footprint. However a comprehensive Life Cycle Assessment (LCA) is essential to compare the most viable solutions for public mobility accounting for variations in weather conditions geographic locations and time horizons. Therefore the present work compares the life cycle environmental impact of different powertrain configurations for urban buses. In particular a series hybrid architecture featuring two possible hydrogenfueled Auxiliary Power Units (APUs) is considered: an H2-Internal Combustion Engine (ICE) and a Fuel Cell (FC). Furthermore a Battery Electric Vehicle (BEV) is considered for the same application. The global warming potential of these powertrains is assessed in comparison to both conventional and hybrid diesel over a typical urban mission profile and in a wide range of external ambient conditions. Given that cabin and battery conditioning significantly influence energy consumption their impact varies considerably between powertrain options. A sensitivity analysis of the BEV battery size is conducted considering the effect of battery preconditioning strategies as well. Furthermore to evaluate the potential of hydrogen and electricity in achieving cleaner public mobility throughout Europe this study examines the effect of different grid carbon intensities on overall emissions based also on a seasonal variability and future projections. Finally the present study demonstrates the strong dependence of the carbon footprint of various technologies on both current and future scenarios identifying a range of boundary conditions suitable for each analysed powertrain option.
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