Publications
Numerical Modelling of Hydrogen Release and Dispersion
Jul 2021
Publication
Hydrogen is the most abundant element on earth being a low polluting and high efficiency fuel that can be used for various applications such as power generation heating or transportation. As a reaction to climate change authorities are working for determining the most promising applications for hydrogen one of the best examples of crossborder initiative being the IPCEI (Important Project of Common European Interest) on Hydrogen under development at EU level. Given the large interest for future uses of hydrogen special safety measures have to be implemented for avoiding potential accidents. If hydrogen is stored and used under pressure accidental leaks from pressure vessels may result in fires or explosions. Worldwide researchers are investigating possible accidents generated by hydrogen leaks. Special attention is granted to the atmospheric dispersion after the release so that to avoid fires or explosions. The use of consequence modelling software within safety and risk studies has shown its’ utility worldwide. In this paper there are modelled the consequences of the accidental release and atmospheric dispersion of hydrogen from a pressure tank using state-of-the-art QRA software. The simulation methodology used in this paper uses the “leak” model for carrying out discharge calculations. This model calculates the release rate and state of the gas after its expansion to atmospheric pressure. Accidental release of hydrogen is modelled by taking into account the process and meteorological conditions and the properties of the release point. Simulation results can be used further for land use planning or may be used for establishing proper protection measures for surrounding facilities. In this work we analysed two possible accident scenarios which may occur at an imaginary hydrogen refuelling station accidents caused by the leaks of the pressure vessel with diameters of 10 and 20 mm for a pressure tank filled with hydrogen at 35 MPa / 70 MPa. Process Hazard Analysis Software Tool 8.4 has been used for assessing the effects of the scenarios and for evaluating the hazardous extent around the analysed installation. Accident simulation results have shown that the leak size has an important effect on the flammable/explosive ranges. Also the jet fire’s influence distance is strongly influenced by the pressure and actual size of the accidental release.
Management of Hybrid Wind and Photovoltaic System Electrolyzer for Green Hydrogen Production and Storage in the Presence of a Small Fleet of Hydrogen Vehicles— An Economic Assessment
Dec 2023
Publication
Nowadays with the need for clean and sustainable energy at its historical peak new equipment strategies and methods have to be developed to reduce environmental pollution. Drastic steps and measures have already been taken on a global scale. Renewable energy sources (RESs) are being installed with a growing rhythm in the power grids. Such installations and operations in power systems must also be economically viable over time to attract more investors thus creating a cycle where green energy e.g. green hydrogen production will be both environmentally friendly and economically beneficial. This work presents a management method for assessing wind–solar– hydrogen (H2 ) energy systems. To optimize component sizing and calculate the cost of the produced H2 the basic procedure of the whole management method includes chronological simulations and economic calculations. The proposed system consists of a wind turbine (WT) a photovoltaic (PV) unit an electrolyzer a compressor a storage tank a fuel cell (FC) and various power converters. The paper presents a case study of green hydrogen production on Sifnos Island in Greece through RES together with a scenario where hydrogen vehicle consumption and RES production are higher during the summer months. Hydrogen stations represent H2 demand. The proposed system is connected to the main power grid of the island to cover the load demand if the RES cannot do this. This study also includes a cost analysis due to the high investment costs. The levelized cost of energy (LCOE) and the cost of the produced H2 are calculated and some future simulations correlated with the main costs of the components of the proposed system are pointed out. The MATLAB language is used for all simulations.
A Two-Stage Robust Optimization Strategy for Long-Term Energy Storage and Cascaded Utilization of Cold and Heat Energy in Peer-to-Peer Electricity Energy Trading
Jan 2025
Publication
This study addresses the optimization of urban integrated energy systems (UIESs) under uncertainty in peer-to-peer (P2P) electricity trading by introducing a two-stage robust optimization strategy. The strategy includes a UIES model with a photovoltaic (PV)–green roof hydrogen storage and cascading cold/heat energy subsystems. The first stage optimizes energy trading volume to maximize social welfare while the second stage maximizes operational profit considering uncertainties in PV generation and power prices. The Nested Column and Constraint Generation (NC&CG) algorithm enhances privacy and solution precision. Case studies with three UIESs show that the model improves economic performance energy efficiency and sustainability increasing profits by 1.5% over non-P2P scenarios. Adjusting the robustness and deviation factors significantly impacts P2P transaction volumes and profits allowing system operators to optimize profits and make risk-aligned decisions.
A Holistic Green System Coupling Hydrogen Production with Wastewater Valorisation
May 2022
Publication
Green hydrogen represents a critical underpinning technology for achievingcarbon neutrality. Although researchers often fixate on its energy inputs atruly ‘green’ hydrogen production process would also be sustainable in termsof water and materials inputs. To address this holistic challenge we demon-strate a new green hydrogen production system which can utilize secondarywastewater as the input (preserving scarce fresh water supplies for drinkingand sanitation). The enabling feature of the proposed system is a self-grownbifunctional CoNi electrode which consists of ultrathin spontaneously depos-ited CoNi nanosheets on a three-dimensional nickel foam. As such a greensynthesis process was developed using an immersion procedure at room-temperature with zero net energy input. Testing revealed that the synthesizedCoNi electrodes can reach a current density of 10 mA cm2 at a small overpo-tential of 197 mV for the hydrogen evolution reaction and 315 mV for the oxy-gen evolution reaction in alkalified wastewater. The values are 16.5%and 6.5% smaller than that from precious catalysts (20 wt% Pt/C and RuO 2 respectively). Importantly this CoNi catalyst offers outstanding durability foroverall wastewater splitting. A prototype solar-energy-powered rooftop waste-water splitting system was constructed and can produce more than 100 Lhydrogen on a sunny day in Sydney Australia. Taken together these resultsindicate that it is promising to unlock holistically green routes for hydrogenproduction by wastewater uplifting with regards to water energy and mate-rials synthesis.
Study on the Performance of Membrane Reactor Using Steam Methane Reforming for Hydrogen Production Heated by HTGR
Jun 2025
Publication
Using High-Temperature Gas-cooled Reactor (HTGR) for hydrogen production through steam methane reforming (SMR) offers advantages such as high hydrogen yield methane savings relatively low cost and ease of scale-up. However due to the limitation of the temperature of the heating helium gas the methane conversion ratio of SMR using HTGR is much lower than that of traditional SMR. The membrane reactor (MR) with its high conversion efficiency compact structure and low cost is a suitable way to improve the methane conversion ratio. This study establishes a one-dimensional reaction flow model for MR heated by the helium gas from HTGR. And the model is validated and applied to analyze the performance of MR. The results show that compared to the original reformer tube MR demonstrates superior performance especially at higher methane conversion ratio and hydrogen yield. And the significant impact of sweep gas and membrane thickness on the performance of MR is discussed in detail. This work offers a new insight into highly enhancing the efficiency of SMR for hydrogen production using HTGR.
Hydrogen as a Panacea for Decarbonising Everything? Exploring Contested Hydrogen Pathways in Germany
Oct 2023
Publication
Technological change is often seen as part of the solution to problems of global sustainability. A wide-ranging literature on how path dependent—often fossil fuel-based—socio-technical configurations can be overcome by more sustainable configurations has emerged over the last two decades. One potential transition pathway to transform electricity heat and mobility systems as well as industrial production is the use of hydrogen. In recent years hydrogen has received increasing attention as part of decarbonisation strategies in many countries as well as by international organisations such as the International Energy Agency or the International Renewable Energy Agency. Also in Germany it has become a central component of climate change policy and is seen by some actors almost as a kind of panacea where the use of hydrogen is expected to decarbonise a wide range of sectors. Policy makers have the ambition for Germany to become a leader in hydrogen development and therefore help to contribute to what Grubler called ‘grand patterns of technological change’. The aim of this paper is to analyse whether relevant actors share expectations for transition pathways based on hydrogen which would foster wide diffusion. Our empirical analysis shows that there are multiple contested pathways both in terms of how hydrogen is produced as well as in which applications or sectors it is to be used. This causes uncertainty and slows down hydrogen developments in Germany. We contribute to an emerging literature on the politics of contested transition pathways and also critically engage with Grubler’s ‘grand patterns’ argument. Results support the idea that the concept of socio-technical pathways allows to expose tensions between competing values and interests. The German government is under considerable pressure regarding competing visions on hydrogen transition pathways. A targeted political prioritisation of hydrogen applications could mitigate tensions and support a shared vision.
Prediction of Hydrogen Production in Proton Exchange Membrane Water Electrolysis via Neural Networks
Sep 2024
Publication
Advancements in water electrolysis technologies are crucial for green hydrogen production. Proton exchange membrane water electrolysis (PEMWE) is characterized by its efficiency and environmental benefits. The pre diction and optimization of hydrogen production rates (HPRs) in PEMWE systems is difficult and still challenging because of the complexity of the system as well as the operational parameters. The integration of artificial in telligence (AI) and machine learning (ML) appears to be effective in optimization within the energy sector. Hence this work employs the artificial neural network (ANN) to develop a model that accurately predicts HPR in PEMWE setups. A novel approach is introduced by employing the Levenberg–Marquardt backpropagation (LMBP) algorithm for training the ANN. This model is designed to predict HPR based on critical operational parameters including anode and cathode areas (mm2 ) cell voltage (V) and current (A) water flow rate (mL/ min) power (W) and temperature (K). The optimized ANN configuration features an architecture with 7 input nodes two hidden layers of 64 neurons each and a single output node. The performance of the ANN model was evaluated against conventional regression models using key metrics: mean squared error (MSE) coefficient of determination (R2 ) and mean absolute error (MAE). The findings of this study reveal that the developed ANN model significantly outperforms traditional models achieving an R2 value of 0.9989 and an MAE of 0.012. In comparison random forest (R2 = 0.9795) linear regression (R2 = 0.9697) and support vector machines (R2 = − 0.4812) show lower predictive accuracy underscoring the ANN model’s superior performance. This work demonstrates the efficiency of the LMBP in enhancing hydrogen production forecasts and sets a foundation for future improvements in PEMWE efficiency. By enabling precise control and optimization of operational pa rameters this study contributes to the broader goal of advancing green hydrogen production as a viable and scalable alternative to fossil fuels offering both immediate and long-term benefits to sustainable energy initiatives.
Enabling Large-scale Enhanced Hydrogen Production in Deep Underground Coal Gasification in the Context of a Hydrogen Economy
Dec 2024
Publication
Underground coal gasification (UCG) is an emerging clean energy technology with significant potential for enhanced hydrogen production especially when coupled with water injection. Previous lab-scale studies have explored this potential but the mechanisms driving water-assisted hydrogen enhancement in large-scale deep UCG settings remain unclear. This study addresses this gap using numerical simulations of a large-scale deep coal model designed for hydrogen-oriented UCG. We investigated single-point and multipoint water injection stra tegies to optimize hydrogen production. Additionally we developed a retractable water injection technique to ensure sustained hydrogen output and effective cavity control. Our results indicate that the water–gas shift re action is crucial for increasing hydrogen production. Multipoint injection has been proven to be more effective than single-point injection increasing hydrogen production by 11% with an equal amount of steam. The introduction of retractable injection allows for continuous and efficient hydrogen generation with daily hydrogen production rates of approximately five times that of a conventional injection scheme and an increase in cumulative hydrogen production of approximately 105% over the same time period. Importantly the mul tipoint injection method also helped limit vertical cavity growth mitigating the risk of aquifer contamination. These findings support the potential of UCG as a low-carbon energy source in the transition to a hydrogen economy
Towards Sustainable Hydrogen Production: An Integrated Approach for Sustainability, Complexity, and Systems Thinking in the Energy Sector
Mar 2024
Publication
The energy sector constitutes a dynamic and complex system indicating that its actions are influenced not just by its individual components but also by the emergent behavior resulting from interactions among them. Moreover there are crucial limitations of previous approaches for addressing the sustainability challenge of the energy sector. Changing transforming and integrating paradigms are the most relevant leverage points for transforming a given system. In other words nowadays the integration of new predominant paradigms in order to provide a unified framework could aim at this actual transformation looking for a sustainable future. This research aims to develop a new unified framework for the integration of the following three paradigms: (1) Sustainability (2) Complexity and (3) Systems Thinking which will be applied to achieving sustainable energy production (using hydrogen production as a case study). The novelty of this work relies on providing a holistic perspective through the integration of the aforementioned paradigms considering the multiple and complex interdependencies among the economy the environment and the economy. For this purpose an integrated seven-stage approach is introduced which explores from the starting point of the integration of paradigms to the application of this integration to sustainable energy production. After applying the Three-Paradigm approach for sustainable hydrogen production as a case study 216 feedback loops are identified due to the emerged complexity linked to the analyzed system. Additionally three system dynamics-based models are developed (by increasing the level of complexity) as part of the application of the Three-Paradigm approach. This research can be of interest to a broad professional audience (e.g. engineers policymakers) as looks into the sustainability of the energy sector from a holistic perspective considering a newly developed Three-Paradigm model considering complexity and using a Systems Thinking approach.
The Future Technological Potential of Hydrogen Fuel Cell Systems for Aviation and Preliminary Co-design of a Hybrid Regional Aircraft Powertrain Through a Mathematical Tool
Feb 2023
Publication
The growing demand for air travel in the commercial sector leads to an increase in global emissions whose mitigation entails transitioning from the current fossil-fuel based generation of aircrafts to a cleaner one within a short timeframe. The use of hydrogen and fuel cells has the potential to reach zero emissions in the aerospace sector provided that required innovation and research efforts are substantially accomplished. Development programs investments and new regulations are needed for this technology to be safe and economical. In this context it makes sense to develop a model-based preliminary design methodology for a hybrid regional aircraft assisted by a battery hybridized fuel cell powertrain. The technological assumptions underlying the study refer to both current and expected data for 2035. The major contribution of the proposed methodology is to provide a mathematical tool that considers the interactions between the choice of components in terms of installed power and energy management. This simultaneous study is done because of the availability of versatile control maps. The tool was then deployed to define current and future technological scenarios for fuel cell battery and hydrogen storage systems by quickly adapting control strategies to different sizing criteria and technical specifications. In this way it is possible to facilitate the estimation of the impact of different sizing criteria and technological features at the aircraft level on the onboard electrical system the management of in-flight power the propulsion methods the impact of the masses on consumption and operational characteristics in a typical flight mission. The proposed combination of advanced sizing and energy management strategies allowed meeting mass and volume constraints with state-of-the-art PEM fuel cell and Li-ion battery specifications. Such a solution corresponds to a high degree of hybridization between the fuel cell system and battery pack (i.e. 300 kW and 750 kWh) whereas projected 2035 specs were demonstrated to help reduce mass and volume by 23 % and 40 % respectively.
Renewable Fuel Production and the Impact of Hydrogen Infrastructure - A Case Study of the Nordics
Apr 2024
Publication
Hard-to-electrify sectors will require renewable fuels to facilitate the green transition in the future. Therefore it is crucial to identify promising production locations while taking into account the local biomass resources variable renewable energy sources and the synergies between sectors. In this study investments and dispatch operations are optimised of a large catalogue of renewable fuel production technologies in the opensource software SpineOpt and this is soft-linked to the comprehensive energy system model Balmorel. We analyse future production pathways by comparing various levels of hydrogen infrastructure including large-scale hydrogen storage and assess system impacts. The results indicate that methanol may provide synergies in its multipurpose use as an early (2030-2040) shipping fuel and later as an aviation fuel through further refining if ammonia becomes more competitive (2050). We furthermore show that a hydrogen infrastructure increases the competitiveness of non-flexible hydrogen-based fuel production technologies. Offshore electrolysis hubs decrease energy system impacts in scenarios with 105 TWh of Nordic hydrogen export. However hydrogen export scenarios are much costlier compared to scenarios with no export unless a high hydrogen price is received. Finally we find that emission taxes in the range of 250-265 euro/tCO2 will be necessary for renewable fuels to become competitive.
A Review on Liquid Hydrogen Fuel Systems in Aircraft Applications for Gas Turbine Engines
Oct 2024
Publication
The transition from traditional aviation fuels to low-emission alternatives such as hydrogen is a crucial step towards a sustainable future for aviation. Conventional jet fuels substantially contribute to greenhouse gas emissions and climate change. Hydrogen fuel especially "green" hydrogen offers great potential for achieving full sustainability in aviation. Hybrid/electric/fuel cell technologies may be used for shorter flights while longrange aircraft are more likely to combust hydrogen in gas turbines. Liquid hydrogen is necessary to minimize storage tank weight but the required fuel systems are at a low technology readiness level and differ significantly from Jet A-1 systems in architecture operation and performance. This paper provides an in-depth review covering the development of liquid hydrogen fuel system design concepts for gas turbines since the 1950s compares insights from key projects such as NASA studies and ENABLEH2 alongside an analysis of recent publications and patent applications and identifies the technological advancements required for achieving zeroemission targets through hydrogen-fuelled propulsion.
Hydrogen Europe Podcast Episode 5 - Industry & Research - Important Cooperation for H2 Sector
Dec 2023
Publication
In this podcast episode Hydrogen Europe CEO Jorgo Chatzimarkakis engages in a dynamic conversation with Hydrogen Europe Research President Luigi Crema. Together they delve into the crucial partnership between industry and research within the hydrogen sector. The episode explores the symbiotic relationship between innovative research initiatives and practical industry applications shedding light on how collaboration fosters advancements in hydrogen technology.
Impact of Green Hydrogen on Climate Change in Peru: An Analysis of Perception, Policies, and Cooperation
Oct 2024
Publication
This research analyzed the impact of green hydrogen (GH) on the dynamics of combating climate change (CC) in Peru for the year 2024 contributing to Sustainable Development Goal 7 focused on affordable and clean energy. The study quantitative and non-experimental in nature used a cross-sectional design and focused on a sample composed of public and private sector officials energy experts and academics evaluating their perception and knowledge about GH and its application in climate policies. The data collection instrument showed good internal consistency with a Cronbach’s alpha value of 0.793. The results revealed that although the adoption of GH is in its early stages it is already considered a vital component in national CC mitigation strategies. A medium positive correlation was identified using the Spearman coefficient (0.418) between GH usage and the effectiveness of mitigation policies as well as its capacity to influence public awareness and promote interinstitutional cooperation. Furthermore it was concluded that the success of GH largely depends on the strengthening of regulatory frameworks investment in infrastructure and the promotion of strategic alliances to facilitate its integration into the national energy matrix. These findings highlight the importance of continuing to develop public policies that promote the use of GH ensuring its sustainability and effectiveness in the fight against climate change in Peru.
Numerical Investigation of the Potential of Using Hydrogen as an Alternative Fuel in an Industrial Burner
Dec 2024
Publication
This study investigates hydrogen and hydrogen-methane mixtures as alternative fuels for industrial burners focusing on combustion dynamics flame stability and emissions. CFD simulations in ANSYS Fluent utilized the RANS framework with the k-ε turbulence model and the mixture fraction/PDF approach. Supporting Python scripts and Cantera-based kinetic modeling employing the GRI-Mech 3.0 mechanism and Zeldovich pathways analyzed equivalence ratios (Φ) adiabatic flame temperatures (Tad) and NOx formation mechanisms. Results revealed non-linear temperature trends with a 50 % hydrogen blend yielding the lowest peak temperature (1880 K) and a 75 % hydrogen blend achieving optimal performance balancing peak temperatures (~1900 K) reduced NOx emissions (5.39 × 10-6) and near-zero CO2 emissions (0.137) though flame stability was impacted by rich mixtures. Pure hydrogen combustion produced the highest peak temperature (2080 K) and NOx emissions (3.82 × 10-5) highlighting the need for NOx mitigation strategies. Mass flow rate (MFR) adjustments and excess air variation significantly influenced emissions with a 25 % MFR increase reducing NOx to 2.8 × 10-5 while higher excess air (e.g. 30 %) raised NOx under lean conditions. Statistical analysis identified Φ hydrogen content (H2%) and flame stability as key factors with 50 %–75 % hydrogen blends minimizing emissions and optimizing performance emphasizing hydrogen’s potential with controlled MFR and air adjustments.
Enhancing Heavy Duty Vehicle Hydrogen Refuelling by Alternative Approach to SAE J2601/2 Protocol and Flow Dynamics
Dec 2024
Publication
This paper analyzes the hydrogen refueling process for heavy-duty vehicles according to the SAE J2601/2 protocol. Attention is paid to two key aspects of the protocol that affect the refueling process: treatment of the storage system from a thermodynamic and geometric point of view and the maximum deliverable flow rate of the station in the refueling process. The effect of the ratio of the inner diameter to the inner length of the total volume on the refueling process was then analyzed and it was shown how far the new approach results deviate from the results obtained by applying the SAE protocol. A total supply of 28 kg was simulated but with three different configurations: 14*2 kg tanks 7*4 kg tanks and 4*7 kg tanks. When analyzing the effect of varying the ratio of inner diameter to inner length it was noted that in the most conservative case there is an overestimation in terms of final temperature for the three configurations of about: 2.1 ◦C 1.4 ◦C and 1.1 ◦C respectively. This aspect has a significant impact on the refueling time which could be reduced by about 9.9% in the first case and about 7.1% and 5.4% in the other two. In addition refueling using the multi-tank approach was simulated for some case studies assimilated to heavy vehicles currently on the market in terms of the amount of hydrogen stored. These refuelings were carried out with stations capable of delivering a maximum flow rate of 120 g/s 180 g/s and 240 g/s. It is inferred that increasing the flow rate from 120 g/s to 180 g/s results in time savings for the three cases of: 35% 34% and 37%. On the other hand running up to 240 g/s results in time savings of: 54% 52% and 55%.
Hydrogen Refueling Infrastructure Design for Personal Mobility Devices using Frugal Engineering Approach
Nov 2012
Publication
More than 150 Hydrogen refueling stations were built around the world in the past 10 years. Much of the technical issues with passenger fuel cell car were discussed and studied. However fuel cell passenger cars are still far from mass production stage. The problem mainly lies with the high cost of fuel cell car production and insufficient hydrogen refueling infrastructure. While the future of fuel cell passenger cars are not clear fuel cell for personal mobility devices like bicycles get more and more attractive. This is mainly due to the simplicity in system design and reducing cost of small size hydrogen fuel cells. But for this technology to be commercialized affordable hydrogen refueling stations is crucial. This study discusses solutions for small sized hydrogen refueling stations based on pressure equalization and simulates the Hydrogen utilization ratio based on different equipment setup. The study is also supported with the experimental data from prototype fuel cell vehicles developed by eMobility in Singapore.
Integration of UN Sustainable Development Goals in National Hydrogen Strategies: A Text Analysis Approach
Jan 2025
Publication
Despite the growing recognition of hydrogen’s potential role in sustainable development there is limited un derstanding of how national hydrogen strategies align with the United Nations Sustainable Development Goals (SDGs). This study addresses this knowledge gap by examining the integration of the SDGs into national hydrogen strategies through text analysis. Among 66 reviewed strategic documents only 15 explicitly reference specific SDGs though SDG-related keywords are widespread particularly regarding SDG 7 (Affordable and Clean Energy) and SDG 13 (Climate Action). Statistical analysis demonstrates a significant link between the presence of hydrogen strategies and both overall SDG performance and progress on most specific SDGs. However countries with hydrogen strategies show lower scores for SDGs 12 (Responsible Consumption and Production) and 13 and there are no significant differences for SDGs 10 (Reduced Inequalities) 14 (Life below Water) and 15 (Life on Land). Our findings highlight the need for more explicit integration of SDGs into hydrogen strategies and better consideration of sustainability synergies and trade-offs providing policymakers with evidence-based guidance for aligning hydrogen strategies with global sustainability objectives.
Functional Resonance Analysis for Emerging Risks in Hydrogen Handling: An Analysis of an Experimental Test
Oct 2024
Publication
Hydrogen is on the rise as a substitute for fossil fuel in the energy sector. While this substitution does not happen dramatically the steady increase in hydrogen related research might be a good indicator of such desire. As it stands there are issues regarding its safe handling and use; consequently the health and safety subsectors observe the situation conspicuously. As we yet to know the behavior of hydrogen in critical situations uncertainties make these tasks prone to emerging risks. Thus hydrogen safety falls under emerging risk studies. Conventional perspective on safety especially regarding the flammable material focuses on calculating the hypothetical risks of failures in system. Resilience Engineering has another perspective as it focuses on normal operations offering new perspectives to tackle emerging risks from a new angle. Born from the heart of Resilience Engineering the Functional Resonance Analysis Method (FRAM) captures sociotechnical systems’ essence in a tangible way. In this study FRAM has been used to model a series of experiments done on hydrogen management to analyze its jet fire. FRAM is used to test whether the method could be suitable to model a system in which emerging risks are present. It is the conclusion of this study that FRAM seems promising in raising risk awareness especially when available data is limited.
Liquid E-fuels for a Sustainable Future: A Comprehensive Review of Production, Regulation, and Technological Innovation
Sep 2025
Publication
The decarbonization of sectors such as aviation maritime transport and heavy-duty mobility—where direct electrification is not yet feasible—requires alternative fuels with high energy density and compatibility with existing infrastructure. This review investigates the potential of liquid synthetic fuels known as liquid electrofuels (or e-fuels) to replace fossil fuels in these hard-to-abate sectors. The objective is to provide a comprehensive integrative assessment of liquid e-fuel development by analyzing production pathways feedstock demands regulatory frameworks and industrial implementation trends. The study reviews three major production processes—Fischer–Tropsch synthesis methanol synthesis and the Haber–Bosch process—used to produce six key synthetic fuels: e-kerosene e-diesel e-methanol e-dimethyl ether e-gasoline and e-ammonia. The methodology includes a systematic review of literature life cycle assessments for water and energy demand and analysis of over 30 large-scale projects worldwide in terms of plant capacity (10–200 MW) production volume capital investment and technology readiness level. Results show that process efficiencies range from 59 % to 89 % with current production costs for synthetic kerosene and methanol varying between 1200–4200 €/ton depending on the pathway and technology maturity. The study finds that polymer electrolyte membrane electrolysis and industrial point-source carbon dioxide capture are the most prevalent technologies among operational plants. Regulatory complexity high capital expenditure and the lack of harmonized sustainability criteria remain key barriers to commercial scaling. This review advances the scientific literature by presenting a novel multi-dimensional framework that connects technical environmental and policy considerations offering a strategic roadmap for accelerating the global deployment of liquid synthetic fuels.
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