Towards Sustainable Blue Hydrogen: Integrating Membrane-based Carbon Capture and Oxygen-enriched Combustion

Blue hydrogen production, typically achieved by combining steam methane reforming with amine-based CO2 capture, is widely considered an economical route towards clean hydrogen. However, it suffers from high energy demands associated with solvent regeneration. To overcome this limitation, we propose a novel hybrid approach integrating steam methane reforming with membrane-based CO2 capture and O2-enriched combustion. Using process simulations, we conducted comprehensive techno-economic and environmental analyses to assess critical parameters affecting the levelised cost of hydrogen (LCOH) and CO2 emissions. Optimal results were obtained at an enriched oxygen level of 30% using vacuum pumping and CO2 capture via feed compression at 11 bar. This configuration achieved an LCOH of ~$1.8/kg H2 and total specific CO2 emissions of ~4.9 kg CO2/kg H2. This aligns closely with conventional blue hydrogen benchmarks, with direct emissions significantly reduced to around 1 kg CO2/kg H2. Additionally, sensitivity analysis showed robust economic performance despite variations in energy prices. Anticipated advancements in membrane technology could reduce the LCOH further to approximately $1.5/kg H2. Thus, this hybrid membrane-based process presents a competitive and sustainable strategy, supporting the achievement of the 2050 net-zero emissions goals in hydrogen production.