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A Review on Industrial Perspectives and Challenges on Material, Manufacturing, Design and Development of Compressed Hydrogen Storage Tanks for the Transportation Sector
Jul 2022
Publication
Hydrogen fuel cell technology is securing a place in the future of advanced mobility and the energy revolution as engineers explore multiple paths in the quest for decarbonization. The feasibility of hydrogen-based fuel cell vehicles particularly relies on the development of safe lightweight and cost-competitive solutions for hydrogen storage. After the demonstration of hundreds of prototype vehicles today commercial hydrogen tanks are in the first stages of market introduction adopting configurations that use composite materials. However production rates remain low and costs high. This paper intends to provide an insight into the evolving scenario of solutions for hydrogen storage in the transportation sector. Current applications in different sectors of transport are covered focusing on their individual requirements. Furthermore this work addresses the efforts to produce economically attractive composite tanks discussing the challenges surrounding material choices and manufacturing practices as well as cutting-edge trends pursued by research and development teams. Key issues in the design and analysis of hydrogen tanks are also discussed. Finally testing and certification requirements are debated once they play a vital role in industry acceptance.
Exergy and Exergoeconomic Analysis for the Proton Exchange Membrane Water Electrolysis under Various Operating Conditions and Design Parameters
Nov 2022
Publication
Integrating the exergy and economic analyses of water electrolyzers is the pivotal way to comprehend the interplay of system costs and improve system performance. For this a 3D numerical model based on COMSOL Multiphysics Software (version 5.6 COMSOL Stockholm Sweden) is integrated with the exergy and exergoeconomic analysis to evaluate the exergoeconomic performance of the proton exchange membrane water electrolysis (PEMWE) under different operating conditions (operating temperature cathode pressure current density) and design parameter (membrane thickness). Further the gas crossover phenomenon is investigated to estimate the impact of gas leakage on analysis reliability under various conditions and criteria. The results reveal that increasing the operating temperature or decreasing the membrane thickness improves both the efficiency and cost of hydrogen exergy while increasing the gas leakage through the membrane. Likewise raising the current density and the cathode pressure lowers the hydrogen exergy cost and improves the economic performance. The increase in exergy destroyed and hydrogen exergy cost as well as the decline in second law efficiency due to the gas crossover are more noticeable at higher pressures. As the cathode pressure rises from 1 to 30 bar at a current density of 10000 A/m2 the increase in exergy destroyed and hydrogen exergy cost as well as the decline in second law efficiency are increased by 37.6 kJ/mol 4.49 USD/GJ and 7.1% respectively. The cheapest green electricity source which is achieved using onshore wind energy and hydropower reduces hydrogen production costs and enhances economic efficiency. The growth in the hydrogen exergy cost is by about 4.23 USD/GJ for a 0.01 USD/kWh increase in electricity price at the current density of 20000 A/m2. All findings would be expected to be quite useful for researchers engaged in the design development and optimization of PEMWE.
Life Cycle Performance of Hydrogen Production via Agro-Industrial Residue Gasification—A Small Scale Power Plant Study
Mar 2018
Publication
This study evaluates the environmental profile of a real biomass-based hydrogen production small-scale (1 MWth) system composed of catalytic candle indirectly heated steam gasifier coupled with zinc oxide (ZnO) guard bed water gas shift (WGS) and pressure swing absorber (PSA) reactors. Environmental performance from cradle-to-gate was investigated by life cycle assessment (LCA) methodology. Biomass production shows high influence over all impact categories. In the syngas production process the main impacts observed are global warming potential (GWP) and acidification potential (AP). Flue gas emission from gasifier burner has the largest proportion of total GWP. The residual off gas use in internal combustion engine (ICE) leads to important environmental savings for all categories. Hydrogen renewability score is computed as 90% due to over 100% decline in non-renewable energy demand. Sensitivity analysis shows that increase in hydrogen production efficiency does not necessarily result in decrease in environmental impacts. In addition economic allocation of environmental charges increases all impact categories especially AP and photochemical oxidation (POFP).
Carbon-free Green Hydrogen Production Process with Induction Heating-based Ammonia Decomposition Reactor
Dec 2022
Publication
This study presents an induction heating-based reactor for ammonia decomposition and to achieve a 150 Nm3 /h carbon-free green hydrogen production process. The developed metallic monolith reactor acts by increasing the reactor temperature through an electromagnetic induction method using renewable-based electricity. As a result hydrogen is produced without the generation of air pollutants such as CO2 which are formed via the conventional production pathway. Furthermore techno-economic analysis was conducted based on exergy and economic analysis to evaluate the feasibility of the developed process. Experimentally the proposed reactor showed an ammonia conversion of 90.0 % at 600 ℃ and 7 barg. Exergy analysis indicated that the total unused exergy accounted for 45.79 % of the total exergy input giving an exergy efficiency of 54.21 % for the overall process. Furthermore the CAPEX and OPEX values are calculated as 1599567 USD and 644719 USD/y respectively; therefore the levelized cost of hydrogen (LCOH) was calculated to be 6.98 USD/kgH2. This study also demonstrated that the LCOH varies with the ammonia feed price and the process capacity and so it would be expected to decrease from 6.98 to 5.33 USD/kgH2 as the hydrogen production capacity is increased from 150 to 500 Nm3 / h. Overall our results confirm the feasibility of carbon-free green hydrogen production on on-site hydrogen refueling stations and they will be expected to advance the development of an environmental hydrogen economy.
The Potential for Hydrogen Ironmaking in New Zealand
Oct 2022
Publication
Globally iron and steel production is responsible for approximately 6.3% of global man-made carbon dioxide emissions because coal is used as both the combustion fuel and chemical reductant. Hydrogen reduction of iron ore offers a potential alternative ‘near-zero-CO2’ route if renewable electrical power is used for both hydrogen electrolysis and reactor heating. This paper discusses key technoeconomic considerations for establishing a hydrogen direct reduced iron (H2-DRI) plant in New Zealand. The location and availability of firm renewable electricity generation is described the experimental feasibility of reducing locally-sourced titanomagnetite irons and in hydrogen is shown and a high-level process flow diagram for a counter-flow electrically heated H2-DRI process is developed. The minimum hydrogen composition of the reactor off-gas is 46% necessitating the inclusion of a hydrogen recycle loop to maximise chemical utilisation of hydrogen and minimize costs. A total electrical energy requirement of 3.24 MWh per tonne of H2-DRI is obtained for the base-case process considered here. Overall a maximum input electricity cost of no more than US$80 per MWh at the plant is required to be cost-competitive with existing carbothermic DRI processes. Production cost savings could be achieved through realistic future improvements in electrolyser efficiency (∼ US$5 per tonne of H2-DRI) and heat exchanger (∼US$3 per tonne). We conclude that commercial H2-DRI production in New Zealand is entirely feasible but will ultimately depend upon the price paid for firm electrical power at the plant.
Sufficiency, Sustainability, and Circularity of Critical Materials for Clean Hydrogen
Jan 2022
Publication
Effective global decarbonization will require an array of solutions across a portfolio of low-carbon resources. One such solution is developing clean hydrogen. This unique fuel has the potential to minimize climate change impacts helping decarbonize hard-to-abate sectors such as heavy industry and global transport while also promoting energy security sustainable growth and job creation. The authors estimate suggest that hydrogen needs to grow seven-fold to support the global energy transition eventually accounting for ten percent of total energy consumption by 2050. A scaleup of this magnitude will increase demand for materials such as aluminum copper iridium nickel platinum vanadium and zinc to support hydrogen technologies - renewable electricity technologies and the electrolyzers for renewable hydrogen carbon storage for low-carbon hydrogen or fuel cells using hydrogen to power transport. This report a joint product of the World Bank and the Hydrogen Council examines these three critical areas. Using new data on the material intensities of key technologies the report estimates the amount of critical minerals needed to scale clean hydrogen. In addition it shows how incorporating sustainable practices and policies for mining and processing materials can help minimize environmental impacts. Key among these approaches is the use of recycled materials innovations in design in order to reduce material intensities and adoption of policies from the Climate Smart Mining (CSM) Framework to reduce impacts to greenhouse gas emissions and water footprint.
Everything About Hydrogen Podcast: Hydrogen on a Global Scale
Aug 2022
Publication
On today’s episode of Everything About Hydrogen we are speaking with Dan Sadler Vice President for UK Low Carbon Solutions at Equinor. Equinor is of course a giant in the global energy sector and is taking a prominent role in the development of the international hydrogen economy with high-profile investments in a number of large-scale production projects in major markets such as the UK. Dan has spent the better part of a decade focused on how to leverage hydrogen’s potential as a fuel for the energy transition and we are excited to have him with us to discuss how Equinor is deploying hydrogen technologies and how he and Equinor expect hydrogen to play a role in a decarbonized energy future.
The podcast can be found on their website.
The podcast can be found on their website.
A Review of Key Components of Hydrogen Recirculation Subsystem for Fuel Cell Vehicles
Jul 2022
Publication
Hydrogen energy and fuel cell technology are critical clean energy roads to pursue carbon neutrality. The proton exchange membrane fuel cell (PEMFC) has a wide range of commercial application prospects due to its simple structure easy portability and quick start-up. However the cost and durability of the PEMFC system are the main barriers to commercial applications of fuel cell vehicles. In this paper the core hydrogen recirculation components of fuel cell vehicles including mechanical hydrogen pumps ejectors and gas–water separators are reviewed in order to understand the problems and challenges in the simulation design and application of these components. The types and working characteristics of mechanical pumps used in PEMFC systems are summarized. Furthermore corresponding design suggestions are given based on the analysis of the design challenges of the mechanical hydrogen pump. The research on structural design and optimization of ejectors for adapting wide power ranges of PEMFC systems is analyzed. The design principle and difficulty of the gas–water separator are summarized and its application in the system is discussed. In final the integration and control of hydrogen recirculation components controlled cooperatively to ensure the stable pressure and hydrogen supply of the fuel cell under dynamic loads are reviewed.
Mathematical Modeling of Unstable Transport in Underground Hydrogen Storage
Apr 2015
Publication
Within the framework of energy transition hydrogen has a great potential as a clean energy carrier. The conversion of electricity into hydrogen for storage and transport is an efficient technological solution capable of significantly reducing the problem of energy shortage. Underground hydrogen storage (UHS) is the best solution to store the large amount of excess electrical energy arising from the excessive over-production of electricity with the objective of balancing the irregular and intermittent energy production typical of renewable sources such as windmills or solar. Earlier studies have demonstrated that UHS should be qualitatively identical to the underground storage of natural gas. Much later however it was revealed that UHS is bound to incur peculiar difficulties as the stored hydrogen is likely to be used by the microorganisms present in the rocks for their metabolism which may cause significant losses of hydrogen. This paper demonstrates that besides microbial activities the hydrodynamic behavior of UHS is very unique and different from that of a natural gas storage.
Recent Progress in Ammonia Fuel Cells and their Potential Applications
Nov 2020
Publication
Conventional technologies are largely powered by fossil fuel exploitation and have ultimately led to extensive environmental concerns. Hydrogen is an excellent carbon-free energy carrier but its storage and long-distance transportation remain big challenges. Ammonia however is a promising indirect hydrogen storage medium that has well-established storage and transportation links to make it an accessible fuel source. Moreover the notion of ‘green ammonia’ synthesised from renewable energy sources is an emerging topic that may open significant markets and provide a pathway to decarbonise a variety of applications reliant on fossil fuels. Herein a comparative study based on the chosen design working principles advantages and disadvantages of direct ammonia fuel cells is summarised. This work aims to review the most recent advances in ammonia fuel cells and demonstrates how close this technology type is to integration with future applications. At present several challenges such as material selection NOx formation CO2 tolerance limited power densities and long-term stability must still be overcome and are also addressed within the contents of this review
Experimental Study on Flame Characteristics of Cryogenic Hydrogen Jet Fire
Sep 2021
Publication
In this work cryogenic hydrogen fires at fixed pressures and various initial temperatures were investigated experimentally. Flame length width heat fluxes and temperatures in down-stream regions were measured for the scenarios with 1.6-3 mm jet nozzle 106 to 273 K 2-5 barabs. The results show that the flame size is related to not only the jet nozzle diameter but also the release pressure and initial temperature. The correlations of normalized flame length and width are proposed with the stagnation pressure and the ratio of ambient and stagnation temperatures. Under constant pressure the flame size total radiative power and radiation fraction increase with the decrease of temperature due to lower choked flow velocity and higher density of cryogenic hydrogen. The correlation of radiation fraction proposed by Molina et al. at room temperature is not suitable to predict the cryogenic hydrogen jet fires. Based on piecewise polynomial law
Quantifying the Potential of Renewable Natural Gas to Support a Reformed Energy Landscape: Estimates for New York State
Jun 2021
Publication
Public attention to climate change challenges our locked-in fossil fuel-dependent energy sector. Natural gas is replacing other fossil fuels in our energy mix. One way to reduce the greenhouse gas (GHG) impact of fossil natural gas is to replace it with renewable natural gas (RNG). The benefits of utilizing RNG are that it has no climate change impact when combusted and utilized in the same applications as fossil natural gas. RNG can be injected into the gas grid used as a transportation fuel or used for heating and electricity generation. Less common applications include utilizing RNG to produce chemicals such as methanol dimethyl ether and ammonia. The GHG impact should be quantified before committing to RNG. This study quantifies the potential production of biogas (i.e. the precursor to RNG) and RNG from agricultural and waste sources in New York State (NYS). It is unique because it is the first study to provide this analysis. The results showed that only about 10% of the state’s resources are used to generate biogas of which a small fraction is processed to RNG on the only two operational RNG facilities in the state. The impact of incorporating a second renewable substitute for fossil natural gas “green” hydrogen is also analyzed. It revealed that injecting RNG and “green” hydrogen gas into the pipeline system can reduce up to 20% of the state’s carbon emissions resulting from fossil natural gas usage which is a significant GHG reduction. Policy analysis for NYS shows that several state and federal policies support RNG production. However the value of RNG can be increased 10-fold by applying a similar incentive policy to California’s Low Carbon Fuel Standard (LCFS).
Fuel-scale Tunnel Experiments for Fuel Cell Hydrogen Vehicles: Gas Dispersion
Sep 2021
Publication
In the framework of the HYTUNNEL-CS European project sponsored by FCH-JU a set of preliminary tests were conducted in a real tunnel in France. These tests are devoted to safety of hydrogen-fueled vehicles having a compressed gas storage and Temperature Pressure Release Device (TPRD). The goal of the study is to develop recommendations for Regulations Codes and Standards (RCS) for inherently safer use of hydrogen vehicles in enclosed transportation systems. In these preliminary tests the helium gas has been employed instead of hydrogen. Upward and downward gas releases following by TPRD activation has been considered. The experimental data describing local behavior (close to jet or below the chassis) as well as global behavior at the tunnel scale are obtained. These experimental data are systematically compared to existing engineering correlations. The results will be used for benchmarking studies using CFD codes. The hydrogen pressure range in these preliminary tests has been lowered down to 20MPa in order to verify the capability of various large-scale measurement techniques before scaling up to 70MPa the subject of the second campaign.
Power-to-Gas Hydrogen: Techno-economic Assessment of Processes Towards a Multi-purpose Energy Carrier
Dec 2016
Publication
The present work investigates Power-to-Gas (PtG) options for variable Renewable Electricity storage into hydrogen through low temperature (alkaline and PEM) and high-temperature (SOEC) water electrolysis technologies. The study provides the assessment of the cost of the final product when hydrogen is employed for mobility (on-site refueling stations) electricity generation (by fuel cells in Power-to-Power systems) and grid injection in the natural gas network. Costs estimations are performed for 2013-2030 scenarios. A case study on the impact of variable Renewable Electricity storage by hydrogen generation on the Italian electricity and mobility sectors is presented.
Green Synthetic Fuels: Renewable Routes for the Conversion of Non-Fossil Feedstocks into Gaseous Fuels and Their End Uses
Jan 2020
Publication
Innovative renewable routes are potentially able to sustain the transition to a decarbonized energy economy. Green synthetic fuels including hydrogen and natural gas are considered viable alternatives to fossil fuels. Indeed they play a fundamental role in those sectors that are difficult to electrify (e.g. road mobility or high-heat industrial processes) are capable of mitigating problems related to flexibility and instantaneous balance of the electric grid are suitable for large-size and long-term storage and can be transported through the gas network. This article is an overview of the overall supply chain including production transport storage and end uses. Available fuel conversion technologies use renewable energy for the catalytic conversion of non-fossil feedstocks into hydrogen and syngas. We will show how relevant technologies involve thermochemical electrochemical and photochemical processes. The syngas quality can be improved by catalytic CO and CO2 methanation reactions for the generation of synthetic natural gas. Finally the produced gaseous fuels could follow several pathways for transport and lead to different final uses. Therefore storage alternatives and gas interchangeability requirements for the safe injection of green fuels in the natural gas network and fuel cells are outlined. Nevertheless the effects of gas quality on combustion emissions and safety are considered.
Progress and Prospects of Hydrogen Production: Opportunities and challenges
Jan 2021
Publication
This study presents an overview of the current status of hydrogen production in relation to the global requirement for energy and resources. Subsequently it symmetrically outlines the advantages and disadvantages of various production routes including fossil fuel/biomass conversion water electrolysis microbial fermentation and photocatalysis (PC) in terms of their technologies economy energy consumption and costs. Considering the characteristics of hydrogen energy and the current infrastructure issues it highlights that onsite production is indispensable and convenient for some special occasions. Finally it briefly summarizes the current industrialization situation and presents future development and research directions such as theoretical research strengthening renewable raw material development process coupling and sustainable energy use.
Emerging Electrochemical Energy Conversion and Storage Technologies
Sep 2014
Publication
Electrochemical cells and systems play a key role in a wide range of industry sectors. These devices are critical enabling technologies for renewable energy; energy management conservation and storage; pollution control/monitoring; and greenhouse gas reduction. A large number of electrochemical energy technologies have been developed in the past. These systems continue to be optimized in terms of cost life time and performance leading to their continued expansion into existing and emerging market sectors. The more established technologies such as deep-cycle batteries and sensors are being joined by emerging technologies such as fuel cells large format lithium-ion batteries electrochemical reactors; ion transport membranes and supercapacitors. This growing demand (multi-billion dollars) for electrochemical energy systems along with the increasing maturity of a number of technologies is having a significant effect on the global research and development effort which is increasing in both in size and depth. A number of new technologies which will have substantial impact on the environment and the way we produce and utilize energy are under development. This paper presents an overview of several emerging electrochemical energy technologies along with a discussion some of the key technical challenges.
Role of Hydrogen-based Energy Carriers as an Alternative Option to Reduce Residual Emissions Associated with Mid-century Decarbonization Goals
Mar 2022
Publication
Hydrogen-based energy carriers including hydrogen ammonia and synthetic hydrocarbons are expected to help reduce residual carbon dioxide emissions in the context of the Paris Agreement goals although their potential has not yet been fully clarified in light of their competitiveness and complementarity with other mitigation options such as electricity biofuels and carbon capture and storage (CCS). This study aimed to explore the role of hydrogen in the global energy system under various mitigation scenarios and technology portfolios using a detailed energy system model that considers various energy technologies including the conversion and use of hydrogen-based energy carriers. The results indicate that the share of hydrogen-based energy carriers generally remains less than 5% of global final energy demand by 2050 in the 2 ◦C scenarios. Nevertheless such carriers contribute to removal of residual emissions from the industry and transport sectors under specific conditions. Their share increases to 10–15% under stringent mitigation scenarios corresponding to 1.5 ◦C warming and scenarios without CCS. The transport sector is the largest consumer accounting for half or more of hydrogen production followed by the industry and power sectors. In addition to direct usage of hydrogen and ammonia synthetic hydrocarbons converted from hydrogen and carbon captured from biomass or direct air capture are attractive transport fuels growing to half of all hydrogen-based energy carriers. Upscaling of electrification and biofuels is another common cost-effective strategy revealing the importance of holistic policy design rather than heavy reliance on hydrogen.
Implementation of Transition Metal Phosphides as Pt-Free Catalysts for PEM Water Electrolysis
Mar 2022
Publication
Proton Exchange Membrane (PEM) water electrolysis (WE) produces H2 with a high degree of purity requiring only water and energy. If the energy is provided from renewable energy sources it releases “Green H2” a CO2 -free H2 . PEMWE uses expensive and rare noble metal catalysts which hinder their use at a large industrial scale. In this work the electrocatalytic properties of Transition Metal Phosphides (TMP) catalysts supported on Carbon Black (CB) for Hydrogen Evolution Reaction (HER) were investigated as an alternative to Platinum Group Metals. The physico-chemical properties and catalytic performance of the synthesized catalysts were characterized. In the ex situ experiments the 25% FeP/CB 50% FeP/CB and 50% CoP/CB with overpotentials of −156.0 −165.9 and −158.5 mV for a current density of 100 mA cm−2 showed the best catalytic properties thereby progressing to the PEMWE tests. In those tests the 50% FeP/CB required an overpotential of 252 mV for a current density of 10 mA cm−2 quite close to the 220 mV of the Pt catalyst. This work provides a proper approach to the synthesis and characterization of TMP supported on carbon materials for the HER paving the way for further research in order to replace the currently used PGM in PEMWE.
Optimal Scheduling of a Hydrogen-Based Energy Hub Considering a Stochastic Multi-Attribute Decision-Making Approach
Jan 2023
Publication
Nowadays the integration of multi-energy carriers is one of the most critical matters in smart energy systems with the aim of meeting sustainable energy development indicators. Hydrogen is referred to as one of the main energy carriers in the future energy industry but its integration into the energy system faces different open challenges which have not yet been comprehensively studied. In this paper a novel day-ahead scheduling is presented to reach the optimal operation of a hydrogen-based energy hub based on a stochastic multi-attribute decision-making approach. In this way the energy hub model is first developed by providing a detailed model of Power-to-Hydrogen (P2H) facilities. Then a new multi-objective problem is given by considering the prosumer’s role in the proposed energy hub model as well as the integrated demand response program (IDRP). The proposed model introduces a comprehensive approach from the analysis of the historical data to the final decision-making with the aim of minimizing the system operation cost and carbon emission. Moreover to deal with system uncertainty the scenario-based method is applied to model the renewable energy resources fluctuation. The proposed problem is defined as mixed-integer non-linear programming (MINLP) and to solve this problem a simple augmented e-constrained (SAUGMECON) method is employed. Finally the simulation of the proposed model is performed on a case study and the obtained results show the effectiveness and benefits of the proposed scheme.
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