Italy
Accelerating Thermally Safe Operating Area Assessment of Ignition Coils for Hydrogen Engines via AI-Driven Power Loss Estimation
Aug 2025
Publication
In order to determine thermally safe driving parameters of ignition coils for hydrogen internal combustion engines (ICE) a reliable estimation of internal power losses is essential. These losses include resistive winding losses magnetic core losses due to hysteresis and eddy currents dielectric losses in the insulation and electronic switching losses. Direct experimental assessment is difficult because the components are inaccessible while conventional computer-aided engineering (CAE) approaches face challenges such as the need for accurate input data the need for detailed 3D models long computation times and uncertainties in loss prediction for complex structures. To address these limitations we propose an artificial intelligence (AI)-based framework for estimating internal losses from external temperature measurements. The method relies on an artificial neural network (ANN) trained to capture the relationship between external coil temperatures and internal power losses. The trained model is then employed within an optimization process to identify losses corresponding to experimental temperature values. Validation is performed by introducing the identified power losses into a CAE thermal model to compare predicted and experimental temperatures. The results show excellent agreement with errors below 3% across the −30 ◦C to 125 ◦C range. This demonstrates that the proposed hybrid ANN–CAE approach achieves high accuracy while reducing experimental effort and computational demand. Furthermore the methodology allows for a straightforward determination of the coil safe operating area (SOA). Starting from estimates derived from fitted linear trends the SOA limits can be efficiently refined through iterative verification with the CAE model. Overall the ANN–CAE framework provides a robust and practical tool to accelerate thermal analysis and support coil development for hydrogen ICE applications.
Electrochemical Oxidation of Guaiacol as a Sacrificial Anodic Process Producing Fine Chemical Derivative, for Hydrogen Production via Electrolysis
Apr 2025
Publication
In this paper we propose an alternative strategy to produce green hydrogen in a more sustainable way than standard water electrolysis where a substantial amount of the electrical energy is wasted in the oxygen evolution quite often simply released in the atmosphere. The HER (hydrogen evolution reaction) is effectively coupled with the oxidation of guaiacol at the anode leading to the simultaneous production of H2 and valuable guaiacol oligomers. Significative points i) a substantial decrease of the potential difference for the HER 0.85 V with guaiacol ii) HER is accompanied by the production of industrially appealing and sustainable guaiacol based oligomers iii) guaiacol oxidation runs efficiently on carbon-based surfaces like graphite and glassy carbon which are cheap and not-strategic materials. Then the electrochemical oxidation mechanism of guaiacol is studied in detail with in-situ EPR measurements and post-electrolysis product characterization: LC-DAD LC-MS and NMR. Experimental results and theoretical calculations suggest that guaiacol polymerization follows a Kane-Maguire mechanism.
Techno-Economic Analysis of Hydrogen Transport via Truck Using Liquid Organic Hydrogen Carriers
Apr 2025
Publication
This study presents a techno-economic analysis of hydrogen transportation via liquid organic hydrogen carriers by road comparing this option with compressed hydrogen (350 bar) and liquefied hydrogen. The analysis includes the simulation of hydrogenation and dehydrogenation reactors for the dibenzyltoluene/perhydro-dibenzyltoluene system using ASPEN Plus along with a cost assessment of compression liquefaction and trucking. A sensitivity analysis is also carried out evaluating hydrogen transport at varying daily demand levels (1 2 and 4 t/d) and transport distances (50 150 and 300 km) with varying electricity prices and capital expenditures for hydrogenation and dehydrogenation units. Results indicate that compressed hydrogen is the most cost-effective solution for short distances up to 150 km with a levelized cost of transported hydrogen ranging from 1.10 to 1.61 EUR/kg. However LOHC technology becomes more competitive at longer distances with LCOTH values between 1.49 and 1.90 EUR/kg at 300 km across all demand levels. Liquefied hydrogen remains the least competitive option reaching costs up to 5.35 EUR/kg although it requires fewer annual trips due to higher trailer capacity. Notably at 150 km LOHC transport becomes more cost-effective than compressed hydrogen when electricity prices exceed 0.22 EUR/kWh or when the capital costs for hydrogenation and dehydrogenation units are minimized. From an environmental perspective switching from compressed to liquid hydrogen carriers significantly reduces CO2 emissions—by 56% for LOHCs and 78% for liquid hydrogen—highlighting the potential of these technologies to support the decarbonization of hydrogen logistics.
A Comprehensive Review on Hydrogen Production via Catalytic Ammonia Decomposition
Aug 2025
Publication
A comprehensive literature review highlights how the nature of active metals support materials promoters and synthesis methods influences catalytic performance with particular attention to ruthenium-based catalysts as the current benchmark. Kinetic models are presented to describe the reaction pathway and predict catalyst behavior. Various reactor configurations including fixed-bed membrane catalytic membrane perovskitebased and microreactors are evaluated in terms of their suitability for ammonia decomposition. While ruthenium remains the benchmark catalyst alternative transition metals such as iron nickel and cobalt have also been investigated although they typically require higher operating temperatures (≥500 °C) to achieve comparable conversion levels. At the industrial scale catalyst development must balance performance with cost. Inexpensive and scalable materials (e.g. MgO Al2O3 CaO K Na) and simple preparation techniques (e.g. wet impregnation incipient wetness) may offer lower performance than more advanced systems but are often favored for practical implementation. From a reactor engineering standpoint membrane reactors emerge as the most promising technology for combining catalytic reaction and product separation in a single unit operation. This review provides a critical overview of current advances in ammonia decomposition for hydrogen production offering insights into both catalytic materials and reactor design strategies for sustainable energy applications.
Mitigating Power Deficits in Lean-Burn Hydrogen Engines with Mild Hybrid Support for Urban Vehicles
Aug 2025
Publication
Hydrogen-fueled internal combustion engines present a promising pathway for reducing carbon emissions in urban transportation by allowing for the reuse of existing vehicle platforms while eliminating carbon dioxide emissions from the exhaust. However operating these engines with lean air–fuel mixtures—necessary to reduce nitrogen oxide emissions and improve thermal efficiency—leads to significant reductions in power output due to the low energy content of hydrogen per unit volume and slower flame propagation. This study investigates whether integrating a mild hybrid electric system operating at 48 volts can mitigate the performance losses associated with lean hydrogen combustion in a small passenger vehicle. A complete simulation was carried out using a validated one-dimensional engine model and a full zero-dimensional vehicle model. A Design of Experiments approach was employed to vary the electric motor size (from 1 to 15 kW) and battery capacity (0.5 to 5 kWh) while maintaining a fixed system voltage optimizing both the component sizing and control strategy. Results showed that the best lean hydrogen hybrid configuration achieved reductions of 18.6% in energy consumption in the New European Driving Cycle and 5.5% in the Worldwide Harmonized Light Vehicles Test Cycle putting its performance on par with the gasoline hybrid benchmark. On average the lean H2 hybrid consumed 41.2 kWh/100 km nearly matching the 41.0 kWh/100 km of the gasoline P0 configuration. Engine usage analysis demonstrated that the mild hybrid system kept the hydrogen engine operating predominantly within its high-efficiency region. These findings confirm that lean hydrogen combustion when supported by appropriately scaled mild hybridization is a viable near-zero-emission solution for urban mobility— delivering competitive efficiency while avoiding tailpipe CO2 and significantly reducing NOx emissions all with reduced reliance on large battery packs.
Lifecycle CO2 Analysis for Urban Emission Reduction of Hydrogen-fuelled and Battery Electric Buses in the European Union Current and Future Energetic Scenarios
Apr 2025
Publication
As the need to reduce Greenhouse Gas (GHG) emissions and dependence on fossil fuels grows new vehicle concepts are emerging as sustainable solutions for urban mobility. Beyond evaluating tailpipe emissions indirect emissions associated with energy and hydrogen production as vehicle manufacturing must be accounted offering a holistic Lifecycle Assessment (LCA) perspective. This study compares Battery Electric Vehicles (BEVs) Fuel Cell Vehicles (FCVs) Hydrogen Internal Combustion Engine Vehicles (H2ICEVs) and hybrid H2ICEVs analyzing energy efficiency and GHG emissions in urban environment across the European Union. Future scenarios (2030 2050) are examined as well with evolving energy mixes and manufacturing impacts. Findings show BEVs as the most efficient configuration with the lowest GHG emissions in 2024 while FCVs become the best option in future scenarios due to greener hydrogen production and improved manufacturing. This study emphasizes the need for tailored strategies to achieve sustainable urban mobility providing insights for policymakers and stakeholders.
Coupling High-temperature Electrolysis and Industrial Waste Heat for On-site Green Hydrogen Production: Energy, Economic and Environmental Analysis
Apr 2025
Publication
High-temperature electrolysis offers a solution for industry decarbonisation by high-efficiency hydrogen production. This study presents a system based on Solid Oxide Electrolysis Cells (SOEC) fed by photovoltaic and waste heat recovery for hydrogen blending with natural gas in industrial burners. The aim of this work is to assess techno-economic feasibility of the proposed configuration investigating hydrogen blending limits Levelized Cost of Hydrogen (LCOH) and decarbonisation cost. LCOH values below 6 €/kgH2 cannot be achieved at current SOEC costs. The system can be applied without significant burner modifications since maximum hydrogen volumetric fractions are less than 20 %. Higher efficiency and emission reduction potential in comparison to alkaline electrolysers can be achieved but they are offset by higher LCOH and carbon abatement costs. Forthcoming reduction in SOEC costs can improve the cost-effectiveness and high natural gas prices experienced during the energy crisis make the decarbonisation cost competitive with the emission trading system.
Computational Thermo-mechanical Modelling and Design-space Exploration of Cryogenic Hydrogen Tanks for Aviation
Aug 2025
Publication
A tool for parametric finite element modeling and analysis of LH2 tanks for aviation is developed. Passively insulated cryogenic composite sandwich pressure vessels are investigated as they conjugate simplicity effectiveness and lightweight design for aeronautical applications. Several parametric analyses are performed with the aim of gaining both general and case-specific understanding of how particular design choices may impact the tank mechanical and thermal performance. Differently from most of previous studies multiple design choices including tank walls thicknesses constraints for airframe integration strategies as well as the presence position and integration of refuelling cutouts and anti-sloshing bulkheads are considered. The thermo-mechanical analyses are performed considering first a simple reference configuration with the aim of evaluating possible directions for performance enhancement. Results indicate how different design features affect the gravimetric and thermal efficiency of the tank without compromising structural integrity if the walls thicknesses are suitably sized. The effects of different constraints and geometric discontinuities which reflect specific fuselage integration choices must be carefully assessed as they reduce safety margins. Ultimately a vessel model including features necessary for safe operation is presented as it serves as a baseline for further optimization.
Advances in Bio-Hydrogen Production: A Critical Review of Pyrolysis Gas Reforming
Apr 2025
Publication
Supplying the growing energy demand of emerging economies by utilizing available biogenic streams will be a key challenge in the coming years. Hydrogen is a promising alternative energy carrier to support the transition of the energy sector and other industries. In recent years the use of biomass as a renewable energy source for bio-based hydrogen production has gained significant attention due to its potential to reduce environmental impact. Among the various thermochemical processes biomass pyrolysis can be used to produce hydrogen though the current use of this process is limited. Reforming the volatile fraction of biomass pyrolysis products has been only marginally explored differently from gasification; the reforming of pyrogasses can then be seen as a viable method to enhance hydrogen yield. This review explores the key factors influencing hydrogen yield including operating conditions and the role of catalysts. It is noteworthy that most of the studies evaluated in this review are in the laboratory and pilot scales and the focus of this study is on the slow pyrolysis process in the first stage. Findings indicate that hydrogen production can be significantly improved with the proper choice of catalysts with metal-based and nonmetal-based catalysts among the most effective. The outcomes of this review highlight the key effect of increasing the reforming temperature and steam-to-biomass ratio to enhance hydrogen production.
Liquefied Hydrogen, Ammonia and Liquid Organic Hydrogen Carriers for Harbour-to-harbour Hydrogen Transport: A Sensitivity Study
Jul 2024
Publication
Hydrogen is commonly perceived as the key player in the transition towards a low-carbon future. Nevertheless H2 low energy density hinders its easy storage and transportation. To address this issue different alternatives (liquefied hydrogen ammonia and liquid organic hydrogen carriers) are explored as hydrogen vectors. The techno-economic assessment of H2 transport through these carriers is strongly dependent on the basis of design adopted such that it is difficult to draw general conclusions. In this respect this work is aimed at performing a sensitivity analysis on the hypotheses introduced in the layout of H2 value chains. Different scenarios are discussed depending on harbour-to-harbour distances cost of utilities and raw materials and H2 application to the industrial or mobility sector. The most cost-effective carrier is selected for each case-study: NH3 is the most advantageous for industrial sector while LH2 holds promises for mobility. Critical issues are pointed out for future large-scale applications.
Optimising Green Hydrogen Production across Europe: How Renewable Energy Sources Shape Plant Design and Costs
Sep 2025
Publication
Green hydrogen is widely recognised as a key enabler for decarbonising heavy industry and long-haul transport. However producing it cost-competitively from variable renewable energy sources presents design challenges. In this study a mixed-integer linear programming (MILP) optimisation framework is developed to minimise the levelised cost of hydrogen (LCOH) from renewable-powered electrolysers. The analysis covers all European countries and explores how wind and solar resource availability influences the optimal sizing of renewable generators electrolysers hydrogen storage and batteries under both current and future scenarios. Results show that renewable resource quality strongly affects system design and hydrogen costs. At present solar-only systems yield LCOH values of 7.4–24.7 €/kg whereas wind-only systems achieve lower costs (5.1–17.1 €/kg) due to higher capacity factors and reduced storage requirements. Hybrid systems combining solar and wind emerge as the most cost-effective solution reducing average LCOH by 57 % compared to solar-only systems and 25 % compared to wind-only systems effectively narrowing geographical cost disparities. In the future scenario LCOH declines to 3–4 €/kg confirming renewable hydrogen’s potential to become economically competitive throughout Europe. A key contribution of this work is the derivation of design guidelines by correlating renewable resource quality with technical energy and economic indicators.
Theoretical Thermal Management Concepts of Recovery Heat Waste in Solid Oxide Fuel Cell System
Oct 2025
Publication
Solid oxide electrolysis cells (SOEC) system has potential to offer an efficient green hydrogen production technology. However the significant cost of this technology is related to the high operating temperatures materials and thermal management including the waste heat. Recovering the waste heat can be conducted through techniques to reduce the overall energy consumption. This approach aims to improve accuracy and efficiency by recovering and reusing the heat that would otherwise be lost. In this paper thermal energy models are proposed based on waste heat recovery methodologies to utilize the heat from outlet fluids within the SOEC system. The mathematical methods for calculating thermal energy and energy transfer in SOEC systems have involved the principles of heat transfer. To address this different simplified thermal models are developed in Simulink Matlab R2025b. The obtained results for estimating proper thermal energy for heating incoming fluids and recycled heat are discussed and compared to determine the efficient and potential thermal model for improvement the waste heat recovery.
Open-Circuit Switch Fault Diagnosis and Accommodation of a Three-Level Interleaved Buck Converter for Electrolyzer Applications
Mar 2023
Publication
This article proposes a novel open-circuit switch fault diagnosis method (FDM) for a three-level interleaved buck converter (TLIBC) in a hydrogen production system based on the water electrolysis process. The control algorithm is suitably modified to ensure the same hydrogen production despite the fault. The TLIBC enables the interfacing of the power source (i.e. low-carbon energy sources) and electrolyzer while driving the hydrogen production of the system in terms of current or voltage. On one hand the TLIBC can guarantee a continuity of operation in case of power switch failures because of its interleaved architecture. On the other hand the appearance of a power switch failure may lead to a loss of performance. Therefore it is crucial to accurately locate the failure in the TLIBC and implement a fault-tolerant control strategy for performance purposes. The proposed FDM relies on the comparison of the shape of the input current and the pulse width modulation (PWM) gate signal of each power switch. Finally an experimental test bench of the hydrogen production system is designed and realized to evaluate the performance of the developed FDM and fault-tolerant control strategy for TLIBC during post-fault operation. It is implemented with a real-time control based on a MicroLabBox dSPACE (dSPACE Paderborn Germany) platform combined with a TI C2000 microcontroller. The obtained simulation and experimental results demonstrate that the proposed FDM can detect open-circuit switch failures in one switching period and reconfigure the control law accordingly to ensure the same current is delivered before the failure.
What is Next in Anion-Exchange Membrane Water Electrolyzers? Bottlenecks, Benefits, and Future
Mar 2022
Publication
As highlighted by the recent roadmaps from the European Union and the United States water electrolysis is the most valuable high-intensity technology for producing green hydrogen. Currently two commercial low-temperature water electrolyzer technologies exist: alkaline water electrolyzer (A-WE) and proton-exchange membrane water electrolyzer (PEM-WE). However both have major drawbacks. A-WE shows low productivity and efficiency while PEM-WE uses a significant amount of critical raw materials. Lately the use of anion-exchange membrane water electrolyzers (AEM-WE) has been proposed to overcome the limitations of the current commercial systems. AEM-WE could become the cornerstone to achieve an intense safe and resilient green hydrogen production to fulfill the hydrogen targets to achieve the 2050 decarbonization goals. Here the status of AEM-WE development is discussed with a focus on the most critical aspects for research and highlighting the potential routes for overcoming the remaining issues. The Review closes with the future perspective on the AEM-WE research indicating the targets to be achieved.
Hybrid Renewable Energy Systems: Integration of Urban Mobility Through Metal Hydrides Solution as an Enabling Technology for Increasing Self-Sufficiency
Oct 2025
Publication
The ongoing energy transition and decarbonization efforts have prompted the development of Hybrid Renewable Energy Systems (HRES) capable of integrating multiple generation and storage technologies to enhance energy autonomy. Among the available options hydrogen has emerged as a versatile energy carrier yet most studies have focused either on stationary applications or on mobility seldom addressing their integration withing a single framework. In particular the potential of Metal Hydride (MH) tanks remains largely underexplored in the context of sector coupling where the same storage unit can simultaneously sustain household demand and provide in-house refueling for lightduty fuel-cell vehicles. This study presents the design and analysis of a residential-scale HRES that combines photovoltaic generation a PEM electrolyzer a lithium-ion battery and MH storage intended for direct integration with a fuel-cell electric microcar. A fully dynamic numerical model was developed to evaluate system interactions and quantify the conditions under which low-pressure MH tanks can be effectively integrated into HRES with particular attention to thermal management and seasonal variability. Two simulation campaigns were carried out to provide both component-level and system-level insights. The first focused on thermal management during hydrogen absorption in the MH tank comparing passive and active cooling strategies. Forced convection reduced absorption time by 44% compared to natural convection while avoiding the additional energy demand associated with thermostatic baths. The second campaign assessed seasonal operation: even under winter irradiance conditions the system ensured continuous household supply and enabled full recharge of two MH tanks every six days in line with the hydrogen requirements of the light vehicle daily commuting profile. Battery support further reduced grid reliance achieving a Grid Dependency Factor as low as 28.8% and enhancing system autonomy during cold periods.
A Flow-Based Approach for the Optimal Location and Sizing of Hydrogen Refueling Stations Along a Highway Corridor
Oct 2025
Publication
The development of hydrogen refueling infrastructure plays a strategic role in enabling the decarbonization of the transport sector especially along major freight and passenger corridors such as the Trans-European Transport Network (TEN-T). Despite the growing interest in hydrogen mobility existing methodologies for the optimal location of hydrogen refueling stations (HRS) remain fragmented and often overlook operational dynamics. Following a review of the existing literature on HRS location models and approaches this study highlights key methodological gaps that hinder effective infrastructure planning. In response a two-stage framework is proposed combining a flow-based location model with a stochastic queueing approach to determine both the optimal placement of HRS and the number of dispensers required at each site. The method is applied to a real segment of the TEN-T network in Northern Italy. The results demonstrate the flexibility of the model in accommodating different hydrogen vehicle penetration scenarios and its utility as a decision-support tool for public authorities and infrastructure planners.
A Critical Assessment of MILD and Plasma-enhanced Combustion for Net-zero Energy Systems using Green Hydrogen and Ammonia
Oct 2025
Publication
The transition to sustainable and smart urban energy systems requires combustion technologies that combine high efficiency with near-zero emissions. Moderate or intense low-oxygen dilution (MILD) combustion has emerged as a promising solution offering volumetric heat release reduced peak temperatures and strong NOX suppression ideal for integrating green hydrogen carriers such as ammonia and ammonia–hydrogen blends into stationary energy systems. While MILD combustion is well-studied for hydrocarbons its application to carbon-free fuels presents challenges including high ignition temperatures low reactivity and potential NOX formation. This review examines the behavior of ammonia-based fuels under MILD conditions mapping combustion regimes across reactor types and operating parameters. To address ignition and stability issues the review also explores plasma-assisted MILD combustion (PAMC). Non-equilibrium plasma (NEP) discharges promote radical generation reduce ignition delay times and enhance flame stability under lean highly diluted conditions. Recent experimental and numerical studies demonstrate that plasma activation can reduce ignition delay times by up to an order of magnitude lower flame lift-off heights by over 30 % in certain configurations and enhance OH radical concentrations and heat release intensity. The extent of these improvements depends on factors such as plasma energy input fuel type and dilution level. This review synthesizes key findings identifies technical gaps and highlights the potential of MILD and PAMC as clean flexible and scalable solutions for low-emission stationary energy generation in smart city environments.
Techno-Economic Assessment of Electrification and Hydrogen Pathways for Optimal Solar Integration in the Glass Industry
Aug 2025
Publication
Direct electrification and hydrogen utilization represent two key pathways for decarbonizing the glass industry with their effectiveness subject to adequate furnace design and renewable energy availability. This study presents a techno-economic assessment for optimal solar energy integration in a representative 300 t/d oxyfuel container glass furnace with a specific energy consumption of 4.35 GJ/t. A mixed-integer linear programming formulation is developed to evaluate specific melting costs carbon emissions and renewable energy self-consumption and self-production rates across three scenarios: direct solar coupling battery storage and a hydrogen-based infrastructure. Battery storage achieves the greatest reductions in specific melting costs and emissions whereas hydrogen integration minimizes electricity export to the grid. By incorporating capital investment considerations the study quantifies the cost premiums and capacity requirements under varying decarbonization targets. A combination of 30 MW of solar plant and 9 MW of electric boosting enables the realization of around 30% carbon reduction while increasing total costs by 25%. Deeper decarbonization targets require more advanced systems with batteries emerging as a cost-effective solution. These findings offer critical insights into the economic and environmental trade-offs as well as the technical constraints associated with renewable energy adoption in the glass industry providing a foundation for strategic energy and decarbonization planning.
Advances in Type IV Tanks for Safe Hydrogen Storage: Materials, Technologies and Challenges
Oct 2025
Publication
This paper provides a comprehensive review of Type IV hydrogen tanks with a focus on materials manufacturing technologies and structural issues related to high-pressure hydrogen storage. Recent advances in the use of advanced composite materials such as carbon fibers and polyamide liners useful for improving mechanical strength and permeability have been reviewed. The present review also discusses solutions to reduce hydrogen blistering and embrittlement as well as exploring geometric optimization methodologies and manufacturing techniques such as helical winding. Additionally emerging technologies such as integrated smart sensors for real-time monitoring of tank performance are explored. The review concludes with an assessment of future trends and potential solutions to overcome current technical limitations with the aim of fostering a wider adoption of Type IV tanks in mobility and stationary applications.
Conceptual Design of a Process for Hydrogen Production from Waste Biomass and its Storage in form of Liquid Ammonia
Feb 2023
Publication
In this work we present the simulation of a plant for the exploitation of renewable hydrogen (e.g. from biomass gasification) with production of renewable ammonia as hydrogen vector and energy storage medium. The simulation and sizing of all unit operations were performed with Aspen Plus® as software. Vegetable waste biomass is used as raw material for hydrogen production more specifically pine sawdust.<br/>The hydrogen production process is based on a gasification reactor operating at high temperature (700–800 °C) in the presence of a gasifying agent such as air or steam. At the outlet a solid residue (ash) and a certain amount of gas which mainly contains H2 CH4 CO and some impurities (e.g. sulphur or chlorine compounds) are obtained. Subsequently this gas stream is purified and treated in a series of reactors in order to maximize the hydrogen yield. In fact after the removal of the sulphur compounds through an absorption column with MEA (to avoid poisoning of the catalytic processes) 3 reactors are arranged in series: Methane Steam Reforming (MSR) High temperature Water-Gas Shift (HT-WGS) Low temperature Water-Gas Shift (LT-WGS).<br/>In the first MSR reactor methane reacts at 1000 °C in presence of steam and a nickel-based catalyst in order to obtain mainly H2 CO and CO2. Subsequently two steps of WGS are present to convert most of the CO into H2 and CO2. Also these reactions are carried out in the presence of a catalyst and with an excess of water.<br/>All the oxygenated compounds must be carefully eliminated: the remaining traces of CO are methanated while CO2 is removed by a basic scrubbing with MEA (35 wt%) inside an absorption column. The Haber-Bosch synthesis of ammonia was carried out at 200 bar and in a temperature range between 300 and 400 °C using two catalysts: Fe (wustite) and Ru/C.<br/>As overall balance from an hourly flow rate of 1000 kg of dry biomass and 600 kg of nitrogen 550 kg of NH3 at 98.8 wt% were obtained demonstrating the proof of concept of this newly designed process for the production of hydrogen from renewable waste biomass and its transformation into a liquid hydrogen vector to be easily transported and stored.
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.
Renewable Electricity and Green Hydrogen Integration for Decarbonization of “Hard-to-Abate” Industrial Sectors
Jul 2024
Publication
This paper investigates hydrogen’s potential to accelerate the energy transition in hardto-abate sectors such as steel petrochemicals glass cement and paper. The goal is to assess how hydrogen produced from renewable sources can foster both industrial decarbonization and the expansion of renewable energy installations especially solar and wind. Hydrogen’s dual role as a fuel and a chemical agent for process innovation is explored with a focus on its ability to enhance energy efficiency and reduce CO2 emissions. Integrating hydrogen with continuous industrial processes minimizes the need for energy storage making it a more efficient solution. Advances in electrolysis achieving efficiencies up to 60% and storage methods consuming about 10% of stored energy for compression are discussed. Specifically in the steel sector hydrogen can replace carbon as a reductant in the direct reduced iron (DRI) process which accounts for around 7% of global steel production. A next-generation DRI plant producing one million tons of steel annually would require approximately 3200 MW of photovoltaic capacity to integrate hydrogen effectively. This study also discusses hydrogen’s role as a co-fuel in steel furnaces. Quantitative analyses show that to support typical industrial plants hydrogen facilities of several hundred to a few thousand MW are necessary. “Virtual” power plants integrating with both the electrical grid and energy-intensive systems are proposed highlighting hydrogen’s critical role in industrial decarbonization and renewable energy growth.
Optimizing Green Hydrogen Production from Wind and Solar for Hard-to-abate Industrial Sectors Across Multiple Sites in Europe
Jul 2024
Publication
This article analyzes a power-to-hydrogen system designed to provide high-temperature heat to hard-to-abate industries. We leverage on a geospatial analysis for wind and solar availability and different industrial demand profiles with the aim to identify the ideal sizing of plant components and the resulting Levelized Cost of Hydrogen (LCOH). We assess the carbon intensity of the produced hydrogen especially when grid electricity is utilized. A methodology is developed to size and optimize the PV and wind energy capacity the electrolyzer unit and hybrid storage by combining compressed hydrogen storage with lithium-ion batteries. The hydrogen demand profile is generated synthetically thus allowing different industrial consumption profiles to be investigated. The LCOH in a baseline scenario ranges from 3.5 to 8.9 €/kg with the lowest values in wind-rich climates. Solar PV only plays a role in locations with high PV full-load hours. It was found that optimal hydrogen storage can cover the users’ demand for 2–3 days. Most of the considered scenarios comply with the emission intensity thresholds set by the EU. A sensitivity analysis reveals that a lower variability of the demand profile is associated with cost savings. An ideally constant demand profile results in a cost reduction of approximately 11 %.
Optimal Design of Hydrogen Delivery Infrastructure for Multi-sector End Uses at Regional Scale
Jul 2024
Publication
Hydrogen is a promising solution for the decarbonisation of several hard-to-abate end uses which are mainly in the industrial and transport sectors. The development of an extensive hydrogen delivery infrastructure is essential to effectively activate and deploy a hydrogen economy connecting production storage and demand. This work adopts a mixed-integer linear programming model to study the cost-optimal design of a future hydrogen infrastructure in presence of cross-sectoral hydrogen uses taking into account spatial and temporal variations multiple production technologies and optimised multi-mode transport and storage. The model is applied to a case study in the region of Sicily in Italy aiming to assess the infrastructural needs to supply the regional demand from transport and industrial sectors and to transfer hydrogen imported from North Africa towards Europe thus accounting for the region’s role as transit point. The analysis integrates multiple production technologies (electrolysis supplied by wind and solar energy steam reforming with carbon capture) and transport options (compressed hydrogen trucks liquid hydrogen trucks pipelines). Results show that the average cost of hydrogen delivered to demand points decreases from 3.75 €/kgH2 to 3.49 €/kgH2 when shifting from mobilityonly to cross-sectoral end uses indicating that the integrated supply chain exploits more efficiently the infrastructural investments. Although pipeline transport emerges as the dominant modality delivery via compressed hydrogen trucks and liquid hydrogen trucks remains relevant even in scenarios characterised by large hydrogen flows as resulting from cross-sectoral demand demonstrating that the system competitiveness is maximised through multi-mode integration.
Optimal Decarbonization Strategies for an Industrial Port Area by Using Hydrogen as Energy Carrier
Jul 2023
Publication
This article discusses possible strategies for decarbonizing the energy systems of an existing port. The approach consists in creating a complete superstructure that includes the use of renewable and fossil energy sources the import or local production of hydrogen vehicles and other equipment powered by Diesel electricity or hydrogen and the associated refuelling and storage units. Two substructures are then identified one including all these options the other considering also the addition of the energy demand of an adjacent steel industry. The goal is to select from each of these two substructures the most cost-effective configurations for 2030 and 2050 that meet the emission targets for those years under different cost scenarios for the energy sources and conversion/storage units obtained from the most reliable forecasts found in the literature. To this end the minimum total cost of all the energy conversion and storage units plus the associated infrastructures is sought by setting up a Mixed Integer Linear Programming optimization problem where integer variables handle the inclusion of the different generation and storage units and their activation in the operational phases. The comprehensive picture of possible solutions set allows identifying which options can most realistically be realized in the years to come in relation to the different assumed cost scenarios. Optimization results related to the scenario projected to 2030 indicate the key role played by Diesel hybrid and electric systems while considering the most stringent or much more stringent scenarios for emissions in 2050 almost all vehicles energy demand and industry hydrogen demand is met by hydrogen imported as ammonia by ship.
Development of a Reliable Simulation Framework for Techno-economic Analyses on Green Hydrogen Production from Wind Farms using Alkaline Electrolyzers
Mar 2024
Publication
The present study investigates the feasibility of coupling the intermittent electric power generation from a wind farm with alkaline electrolyzers to produce green hydrogen. A physically accurate model of commercial elec trolytic modules has been first developed accounting for conversion efficiency drop due to modules’ cool down effects of shutdowns due to the intermittence of wind power and voltage degradation over the working time frame. The model has been calibrated on real modules for which industrial data were available. Three com mercial module sizes have been considered i.e. 1 2 and 4 MW. As a second step the model has been coupled with historical power datasets coming from a real wind farm characterized by a nominal installed power of 13.8 MW. Finally the model was implemented within a sizing algorithm to find the best combination between the actual wind farm power output and the electrolyzer capacity to reach the lowest Levelized Cost Of Hydrogen (LCOH) possible. To this end realistic data for the capital cost of the whole system (wind farm and electrolyzers) have been considered based on industrial data and market reports as well as maintenance costs including both periodic replacements of degraded components and periodic maintenance. Simulations showed that if the right sizing of the two systems is made competitive hydrogen production costs can be achieved even with current technologies. Bigger modules are less flexible but by now considerably cheaper than smaller ones. A future economy of scale in alkaline electrolyzers is then needed to foster the diffusion of the technology.
Strategic Overview on Fuel Cell-Based Systems for Mobility and Electrolytic Cells for Hydrogen Production
Mar 2022
Publication
Given the global effort to embrace research actions and technology enhancement for the energy transition innovative sustainable systems are needed both for energy production and for those sectors that are responsible for high pollution and CO2 emissions. In this context electrolytic cells and fuel cells in their variety and flexibility are energy systems characterized by high efficiency and important performance guaranteeing a sustainable solution for future energy systems and for the circular economy. The scope of this paper is therefore to present the state of the art of such systems. An overview of the electrolyzers for hydrogen production is presented by detailing the level of applications for their different technologies from low-temperature units to high-temperature units the fuel flexibility the electrolysis and co-electrolysis mode and the potential coupling with renewable sources. Fuel cell-based systems are also presented and their application in the mobility sector is investigated by considering road transport with light-duty and heavy-duty applications and marine transport. A comparison with conventional technologies will be also presented providing some hints on the potential applications of electrolytic cells and fuel cell systems given their important contribution to the sustainable and circular economy.
Addressing Environmental Challenges: The Role of Hydrogen Technologies in a Sustainable Future
Dec 2023
Publication
Energy and environmental issues are of great importance in the present era. The transition to renewable energy sources necessitates technological political and behavioral transformations. Hydrogen is a promising solution and many countries are investing in the hydrogen economy. Global demand for hydrogen is expected to reach 120 million tonnes by 2024. The incorporation of hydrogen for efficient energy transport and storage and its integration into the transport sector are crucial measures. However to fully develop a hydrogen-based economy the sustainability and safety of hydrogen in all its applications must be ensured. This work describes and compares different technologies for hydrogen production storage and utilization (especially in fuel cell applications) with focus on the research activities under study at SaRAH group of the University of Naples Federico II. More precisely the focus is on the production of hydrogen from bio-alcohols and its storage in formate solutions produced from renewable sources such as biomass or carbon dioxide. In addition the use of materials inspired by nature including biowaste as feedstock to produce porous electrodes for fuel cell applications is presented. We hope that this review can be useful to stimulate more focused and fruitful research in this area and that it can open new avenues for the development of sustainable hydrogen technologies.
Techno-economic Analysis of Wind-powered Green Hydrogen Production to Facilitate the Decarbonization of Hard-to-abate Sectors: A Case Study on Steelmaking
Apr 2023
Publication
Green hydrogen is among the most promising energy vectors that may enable the decarbonization of our society. The present study addresses the decarbonization of hard-to-abate sectors via the deployment of sustainable alternatives to current technologies and processes where the complete replacement of fossil fuels is deemed not nearly immediate. In particular the investigated case study tackles the emission reduction potential of steelmaking in the Italian industrial framework via the implementation of dedicated green hydrogen production systems to feed Hydrogen Direct Reduction process the main alternative to the traditional polluting routes towards emissions abatement. Green hydrogen is produced via the coupling of an onshore wind farm with lithium-ion batteries alkaline type electrolyzers and the interaction with the electricity grid. Building on a power generation dataset from a real utility-scale wind farm techno-economic analyses are carried out for a large number of system configurations varying components size and layout to assess its performance on the basis of two main key parameters the levelized cost of hydrogen (LCOH) and the Green Index (GI) the latter presented for the first time in this study. The optimal system design and operation logics are investigated accounting for the necessity of providing a constant mass flow rate of H2 and thus considering the interaction with the electricity network instead of relying solely on RES surplus. In-house-developed models that account for performances degradation over time of different technologies are adapted and used for the case study. The effect of different storage technologies is evaluated via a sensitivity analysis on different components and electricity pricing strategy to understand how to favour green hydrogen penetration in the heavy industry. Furthermore for a better comprehension and contextualization of the proposed solutions their emission-reduction potential is quantified and presented in comparison with the current scenario of EU-27 countries. In the optimal case the emission intensity related to the steel making process can be lowered to 235 kg of CO2 per ton of output steel 88 % less than the traditional route. A higher cost of the process must be accounted resulting in an LCOH of such solutions around 6.5 €/kg.
Hierarchical Model Predictive Control for Islanded and Grid-connected Microgrids with Wind Generation and Hydrogen Energy Storage Systems
Aug 2023
Publication
This paper presents a novel energy management strategy (EMS) to control a wind-hydrogen microgrid which includes a wind turbine paired with a hydrogen-based energy storage system (HESS) i.e. hydrogen production storage and re-electrification facilities and a local load. This complies with the mini-grid use case as per the IEA-HIA Task 24 Final Report where three different use cases and configurations of wind farms paired with HESS are proposed in order to promote the integration of wind energy into the grid. Hydrogen production surpluses by wind generation are stored and used to provide a demand-side management solution for energy supply to the local and contractual loads both in the grid-islanded and connected modes with corresponding different control objectives. The EMS is based on a hierarchical model predictive control (MPC) in which long-term and short-term operations are addressed. The long-term operations are managed by a high-level MPC in which power production by wind generation and load demand forecasts are considered in combination with day-ahead market participation. Accordingly the hydrogen production and re-electrification are scheduled so as to jointly track the load demand maximize the revenue through electricity market participation and minimize the HESS operating costs. Instead the management of the short-term operations is entrusted to a low-level MPC which compensates for any deviations of the actual conditions from the forecasts and refines the power production so as to address the real-time market participation and the short time-scale equipment dynamics and constraints. Both levels also take into account operation requirements and devices’ operating ranges through appropriate constraints. The mathematical modeling relies on the mixed-logic dynamic (MLD) framework so that the various logic states and corresponding continuous dynamics of the HESS are considered. This results in a mixed-integer linear program which is solved numerically. The effectiveness of the controller is analyzed by simulations which are carried out using wind forecasts and spot prices of a wind farm in center-south of Italy.
The Potential of Hydrogen-battery Storage Systems for a Sustainable Renewable-based Electrification of Remote Islands in Norway
Oct 2023
Publication
Remote locations and off-grid regions still rely mainly on diesel generators despite the high operating costs and greenhouse gas emissions. The exploitation of local renewable energy sources (RES) in combination with energy storage technologies can be a promising solution for the sustainable electrification of these areas. The aim of this work is to investigate the potential for decarbonizing remote islands in Norway by installing RES-based energy systems with hydrogen-battery storage. A national scale assessment is presented: first Norwegian islands are characterized and classified according to geographical location number of inhabitants key services and current electrification system. Then 138 suitable installation sites are pinpointed through a multiple-step sorting procedure and finally 10 reference islands are identified as representative case studies. A site-specific methodology is applied to estimate the electrical load profiles of all the selected reference islands. An optimization framework is then developed to determine the optimal system configuration that minimizes the levelized cost of electricity (LCOE) while ensuring a reliable 100% renewable power supply. The LCOE of the RES-based energy systems range from 0.21 to 0.63 €/kWh and a clear linear correlation with the wind farm capacity factor is observed (R2 equal to 0.87). Hydrogen is found to be crucial to prevent the oversizing of the RES generators and batteries and ensure long-term storage capacity. The techno-economic feasibility of alternative electrification strategies is also investigated: the use of diesel generators is not economically viable (0.87–1.04 €/kWh) while the profitability of submarine cable connections is highly dependent on the cable length and the annual electricity consumption (0.14–1.47 €/kWh). Overall the cost-effectiveness of RES-based energy systems for off-grid locations in Northern Europe can be easily assessed using the correlations derived in this analysis.
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