Applications & Pathways
Hybrid Renewable Energy Systems for Off-Grid Electrification: A Comprehensive Review of Storage Technologies, Metaheuristic Optimization Approaches and Key Challenges
Nov 2025
Publication
Hybrid Renewable Energy Systems (HRESs) are a practical solution for providing reliable low-carbon electricity to off-grid and remote communities. This review examines the role of energy storage within HRESs by systematically comparing electrochemical mechanical thermal and hydrogen-based technologies in terms of technical performance lifecycle cost operational constraints and environmental impact. We synthesize findings from implemented off-grid projects across multiple countries to evaluate real-world performance metrics including renewable fraction expected energy not supplied (EENS) lifecycle cost and operation & maintenance burdens. Special attention is given to the emerging role of hydrogen as a long-term and cross-sector energy carrier addressing its technical regulatory and financial barriers to widespread deployment. In addition the paper reviews real-world implementations of off-grid HRES in various countries summarizing practical outcomes and lessons for system design and policy. The discussion also includes recent advances in metaheuristic optimization algorithms which have improved planning efficiency system reliability and cost-effectiveness. By combining technological operational and policy perspectives this review identifies current challenges and future directions for developing sustainable resilient and economically viable HRES that can accelerate equitable electrification in remote areas. Finally the review outlines key limitations and future directions calling for more systematic quantitative studies long-term field validation of emerging technologies and the development of intelligent Artificial Intelligence (AI)-driven energy management systems within broader socio-techno-economic frameworks. Overall this work offers concise insights to guide researchers and policymakers in advancing the practical deployment of sustainable and resilient HRES.
Hydrogen Blending as a Transitional Solution for Decarbonizing the Jordanian Electricity Generation Sector
Nov 2025
Publication
While renewable energy deployment has accelerated in recent years fossil fuels continue to play a dominant role in electricity generation worldwide. This necessitates the development of transitional strategies to mitigate greenhouse gas emissions from this sector while gradually reducing reliance on fossil fuels. This study investigates the potential of blending green hydrogen with natural gas as a transitional solution to decarbonize Jordan’s electricity sector. The research presents a comprehensive techno-economic and environmental assessment evaluating the compatibility of the Arab Gas Pipeline and major power plants with hydrogen–natural gas mixtures considering blending limits energy needs environmental impacts and economic feasibility under Jordan’s 2030 energy scenario. The findings reveal that hydrogen blending between 5 and 20 percent can be technically achieved without major infrastructure modifications. The total hydrogen demand is estimated at 24.75 million kilograms per year with a reduction of 152.7 thousand tons of carbon dioxide per annum. This requires 296980 cubic meters of water per year equivalent to only 0.1 percent of the National Water Carrier’s capacity indicating a negligible impact on national water resources. Although technically and environmentally feasible the project remains economically constrained requiring a carbon price of $1835.8 per ton of carbon dioxide for economic neutrality.
Green Hydrogen as a Decarbonization Pathway for Steel Industry in Pakistan
Nov 2025
Publication
The global steel industry emits 1.92 tons of CO2 per ton of output and faces urgent pressure to decarbonize. In Pakistan the sector accounts for 0.29 tons of CO2 per ton of output with limited mitigation frameworks in place. Green hydrogen (GH2)-based steelmaking offers a strategic pathway toward decarbonization. However realizing its potential depends on access to renewable energy. Despite Pakistan’s substantial technical wind potential of 340 GW grid limitations currently restrict wind power to only 4% of national electricity generation. This study explores GH2 production through sector coupling and power wheeling repurposing curtailed wind energy from Sindh to supply Karachi’s steel industry and proposing a phased roadmap for GH enabling fossil fuel substitution industrial resilience and alignment with global carbon-border regulations.
An Effective Integrated Optimal Day-ahead and Real-time Power Scheduling Approach for Hydrogen-based Microgrid
Oct 2025
Publication
The increasing penetration of renewable energy sources in power systems poses significant challenges for maintaining grid reliability mainly due to the variability and uncertainty of solar and demand profiles. Microgrids equipped with diverse storage technologies have emerged as a promising solution to address these issues.This paper proposes an integrated day-ahead and real-time power scheduling approach for grid-connected microgrids equipped with both conventional and hydrogen-based ESSs. While existing strategies often address day-ahead and real-time scheduling separately or rely on a single storage technology this work introduces a unified framework that exploits the complementary characteristics of batteries and hydrogen systems. The proposed approach is based on a novel two-stage stochastic optimization model embedded within a hierarchical optimization framework to address these two intertwined problems efficiently. For the day-ahead scheduling a two-stage stochastic programming energy management model is solved to optimize the microgrid schedule based on forecasted load demand and PV production profiles. Building upon the day-ahead schedule another optimization model is solved which addresses real-time power imbalances caused by deviations in actual PV production and load demand power profiles with respect to the forecasted ones with the aim of minimizing operational disruptions. Simulation results demonstrate the validity of the proposed approach achieving both cost reductions and minimal power imbalances. By dynamically adjusting energy flows and using both conventional batteries and hydrogen systems the proposed approach ensures improved reliability reduced operational costs and enhanced integration of RES in microgrids. These findings highlight the potential of the proposed hierarchical framework to support the large-scale deployment of RES while ensuring resilient and cost-effective microgrid operations.
Blockchain-based Traceability and Certifications of Hydrogen Refueling Station Components
Oct 2025
Publication
As hydrogen gains prominence in energy systems its adoption as an energy source for fuel cell electric vehicles (FCEVs) necessitates the establishment of hydrogen refueling stations (HRS). These stations contain critical compo-nents including nozzles storage tanks heat exchangers and compressors which must be certified by regulatory agen-cies to ensure safety and public trust. Current certification processes are fragmented and manually intensive creating inefficiencies and limiting transparency across the infrastructure lifecycle. In this paper we propose a blockchain-based solution that creates a secure and auditable network for certifying key HRS components. The system integrates an EVM-compatible blockchain decentralized storage and a modular suite of smart contracts (SCs) that formalize registration bidding accreditation certification and governance. Each contract encodes a distinct actor-driven work-flow enabling traceable and role-specific operations. A Decentralized Application (DApp) interface supports real-time and role-based interaction across the ecosystem. We present and evaluate the SCs and their underlying algorithms us-ing gas usage analysis load testing and security auditing. Load testing across the certification lifecycle shows stable transaction throughput and predictable cost profiles under increasing actor activity. A static security analysis con-firms resilience against common vulnerabilities. Our cost analysis indicates that while the framework is technically deployable on public blockchains the execution costs of certain functions make it more cost-effective for private blockchains or Layer 2 networks. We also compare our framework with existing systems to highlight its novelty and technical advantages. Our SCs DApp interface and load testing scripts are publicly available on GitHub.
Uncertainty Ahead: Should Stand-alone Energy Systems Bet on Hydrogen Backup?
Oct 2025
Publication
Achieving net zero by 2050 will require decarbonising stand-alone energy applications. Hydrogen is increasingly viewed as a promising energy carrier but its economic viability remains uncertain due to the lack of consensus on future demand and limited deployment of key components such as fuel cells in stationary stand-alone applications. This study investigates whether hybridising batteries with hydrogen can deliver meaningful cost benefits under future cost trajectories. Using a Monte Carlo framework we simulate 8000 scenarios across constant and seasonal load profiles varying the capital costs of batteries fuel cells electrolysers and hydrogen tanks based on 2025 estimates and 2050 projections. Our results show that hydrogen integration only becomes economically attractive when multiple component costs decline simultaneously. The fuel cell-to-battery power capital cost ratio emerges as the dominant driver of levelised cost of energy (LCOE) improvements. For constant loads median LCOE savings remain below 12 % with more than 5 % savings only achieved when the fuel cell cost is less than 7 times that of the battery. Seasonal nighttime loads offer a wider theoretical LCOE savings range (0–156 %) but substantial gains occur only under unrealistic cost mixes where battery costs remain high and fuel cell costs fall sharply. These findings highlight the sensitivity of hydrogen viability to load profile characteristics and cost interdependencies. They underscore the need for targeted cost reduction strategies particularly for fuel cells to justify added system complexity. These findings are important considerations for future investment and policy decisions.
Life Cycle Assessment of Hydrogen-based Fuels Use in Internal Combustion Engines of Container Ships until 2050
Oct 2025
Publication
Hydrogen-based fuels are potential candidates to help international shipping achieve net-zero greenhouse gas (GHG) emissions by around 2050. This paper quantifies the environmental impacts of liquid hydrogen liquid ammonia and methanol used in a Post-Panamax container ship from 2020 to 2050. It considers cargo capacity changes electricity decarbonization and hydrogen production transitions under two International Energy Agency scenarios: the Stated Policies Scenario (STEPS) and the Net Zero Emissions by 2050 Scenario (NZE). Results show that compared to the existing HFO ship hydrogen-based propulsion systems can decrease cargo weight capacity by 0.3 % to 25 %. In the NZE scenario hydrogen-based fuels can reduce GHG emissions per tonne-nautical mile by 48 %–65 % compared to heavy fuel oil by 2050. Even with fully renewable hydrogenbased fuels 18 %–31 % of GHG emissions would still remain. Using hydrogen-based fuels in internal combustion engines requires attention to minimize environmental trade-offs.
Modeling Electrochemical Impedance Spectroscopy of Hydrogen Complexes During Hydrogen Evolution on Single-stom Electrocatalysts
Nov 2025
Publication
Single Atom Catalysts (SACs) are an emerging frontier in heterogeneous electrocatalysis. They are made of metal atoms atomically dispersed on a matrix. A lot of attention has been dedicated to the study of Hydrogen Evolution Reaction (HER) mechanism due to its relevance in energy conversion technologies both with computational and experimental methods. The classical HER mechanism can be described by a Volmer–Heyrovsky–Tafel mechanism where the two desorption steps are competitive. The Volmer-Heyrovsky mechanism is conventionally proposed for single-atom catalysts. It has been computationally demonstrated that hydrogen complexes can form on SACs due to their analogy with homogeneous catalysts. Unfortunately it is hard to “visualize” these species experimentally. Electrochemical Impedance Spectroscopy (EIS) could be the most promising approach to study electrocatalytic mechanisms. In this work we present microkinetic and Electrochemical Impedance Spectroscopy models for HER on SACs describing Volmer-Heyrovsky and a mechanism mediated by the formation of hydrogen complexes. Our simulated data applied to a case study based on Pd@TiN show that Tafel plots will not suffice in the visualization of hydrogen complexes formation and will need the support of electrochemical impedance spectra in order to clarify the correct mechanism.
The Development of an Analysis Framework for the Integration of Low-carbon Hydrogen into Multi-regional Natural Gas Energy Systems
Nov 2025
Publication
In 2023 global carbon dioxide emissions reached 40 billion tonnes 60 % more than in 1990 intensifying climate concerns. This study explores hydrogen-natural gas blending as a transitional strategy for decarbonization across several regions and energy sectors – residential commercial industrial and agricultural. A multi-regional analysis framework evaluates integration of 20 % by volume low-carbon hydrogen blending into natural gas systems by identifying hydrogen producers importers and exporters based on production and import costs. Applied to Canada 528 scenarios (2026–2050) assess inter-regional hydrogen trade within Canadian provinces. The lowest-cost scenario involves Alberta exporting hydrogen produced through autothermal reforming with 91 % carbon capture and storage and British Columbia producing its own. The grid electrolysis scenario achieves the highest GHG reductions with a 4.5 % GHG mitigation in Canada with full energy system representation. These findings provide insights for policymakers and stakeholders in advancing hydrogen infrastructure and decarbonization strategies.
Techno-economic Analysis of Technologies for Decarbonizing Low- and Medium-Temperature Industrial Heat
Dec 2025
Publication
Decarbonizing industrial heat is critical for achieving climate targets. This study evaluates the economic viability of technologies for decarbonizing industrial heat in Europe through a techno-economic analysis. High-temperature heat pumps (HTHPs) and electric hydrogen and biomass boilers are compared in terms of levelized cost of heat (LCOH) under various scenarios including the impact of thermal storage leveraging dynamic electricity prices. In scenarios for the year 2030 we show that HTHPs leveraging free excess heat achieve LCOH values at least 30% to 60% lower than hydrogen boilers and up to 37% lower than biomass boilers. Integrating daily thermal storage reduces LCOH by up to 15% for heat pumps and 27% for electric boilers. By 2050 anticipated cost and efficiency improvements further enhance the competitiveness of heat pumps. These results highlight the economic advantage of HTHPs particularly when integrating excess heat and thermal storage.
Hydrogen Reduction of Combusted Iron Powder: Role of the Fluidization Regime on the Conversion
Nov 2025
Publication
Fluidized bed systems play a crucial role in industrial processes such as combustion and gasification. In the Iron Power Cycle fluidized bed systems are essential for enabling the reduction of combusted iron back to iron making them a critical component in the regeneration step of the cycle. This study investigates the impact of operating gas velocity on conversion by performing reduction experiments at three distinct fluidization numbers (us/umf): 16 (bubbling regime) 55 (transition region) and 100 (fully turbulent regime). Experiments were conducted to determine the appropriate velocities for each regime ensuring optimal fluidization conditions across reduction temperatures ranging from 500 to 700 ⚬C. The results reveal that conversion rates increase significantly with gas velocities. At 500 ⚬C operating at approximately six times higher velocity leads to a sixfold improvement in conversion when using iron-oxide particles with a Sauter mean diameter of 61 µm. However while enhanced velocities improve reaction efficiency challenges remain at elevated temperatures (T ≥ 500 ⚬C) where iron undergoes defluidization when exposed to hydrogen. Once defluidization occurs refluidization proves impossible with either hydrogen or nitrogen raising concerns about process stability. These insights highlight the potential for optimizing fluidized bed reduction through velocity control while also underscoring the need for additional measures to mitigate unstable fluidization during high-temperature iron oxide reduction.
Techno-economic Assessment of Retrofitted Combined-cycles for Power-to-hydrogen-to-power Systems in European Electricity Markets
Oct 2025
Publication
This paper investigates the performance and economic viability of Combined Cycle Gas Turbines (CCGT) operating on natural gas (NG) and hydrogen within the context of evolving electricity markets. The study is structured into several sections beginning with a benchmark analysis to establish baseline performance metrics including break-even prices and price margins for CCGTs running on NG. The research then explores various base cases and sensitivity analyses focusing on different CCGT capacity factors and the uncertainties surrounding key parameters. The study also compares the performance of CCGTs across different European countries highlighting the impact of increased price fluctuations in forecasted electricity markets. Additionally the paper examines Power-to-X-to-Power (P2X2P) configurations assessing the economic feasibility of hydrogen production and its integration into CCGT operations. The analysis considers scenarios where hydrogen is sourced externally or produced on-site using renewable energy or grid electricity during off-peak hours. The results provide insights into the competitiveness and adaptability of CCGTs in a transitioning energy landscape emphasizing the potential role of hydrogen as a flexible and sustainable energy carrier.
Applied Simulation Study of a Metal Hydride Refrigeration System for Fuel Cell Trucks
Oct 2025
Publication
Refrigeration units in semi-trucks or rigged-body trucks have an energy demand of 8.2–12.4 MWh/y and emit 524.26 kt CO2e/y in Germany. Electrification with fuel cell systems reduces the CO2 emission but an increase of efficiency is necessary because of rapidly increasing hydrogen costs. A metal hydride refrigeration system can increase the efficiency. Even though it was already demonstrated in lab scale with 900 W this power is not sufficient to support a truck refrigeration system and the power output of the lab system was not controllable. Here we show the design and validation of a MATLAB© Simulink model of this metal hydride refrigeration system and its suitability for high power applications with a scaled-up reactor. It was scaled up to rated power of 5 kW and efficiency improvements with an advanced valve switching as well as a controlled cooling pump were implemented. Two application-relevant use cases with hydrogen mass flows from hydrogen fuel cell truck systems were analyzed. The simulation results of these use cases provide an average cooling power of 4.2 and 6.1 kW. Additionally the control of the coolant mass flow at different temperature levels a controlled hydrogen mass flow with a bypass system and an advanced valve switching mechanism increased the system efficiency of the total refrigeration system by 30 % overall.
Energy Management of Hybrid Energy System Considering a Demand-Side Management Strategy and Hydrogen Storage System
Oct 2025
Publication
Nadia Gouda and
Hamed Aly
A hybrid energy system (HES) integrates various energy resources to attain synchronized energy output. However HES faces significant challenges due to rising energy consumption the expenses of using multiple sources increased emissions due to non-renewable energy resources etc. This study aims to develop an energy management strategy for distribution grids (DGs) by incorporating a hydrogen storage system (HSS) and demand-side management strategy (DSM) through the design of a multi-objective optimization technique. The primary focus is on optimizing operational costs and reducing pollution. These are approached as minimization problems while also addressing the challenge of achieving a high penetration of renewable energy resources framed as a maximization problem. The third objective function is introduced through the implementation of the demand-side management strategy aiming to minimize the energy gap between initial demand and consumption. This DSM strategy is designed around consumers with three types of loads: sheddable loads non-sheddable loads and shiftable loads. To establish a bidirectional communication link between the grid and consumers by utilizing a distribution grid operator (DGO). Additionally the uncertain behavior of wind solar and demand is modeled using probability distribution functions: Weibull for wind PDF beta for solar and Gaussian PDF for demand. To tackle this tri-objective optimization problem this work proposes a hybrid approach that combines well-known techniques namely the non-dominated sorting genetic algorithm II and multi-objective particle swarm optimization (Hybrid-NSGA-II-MOPSO). Simulation results demonstrate the effectiveness of the proposed model in optimizing the tri-objective problem while considering various constraints.
Decarbonising Sustainable Aviation Fuel (SAF) Pathways: Emerging Perspectives on Hydrogen Integration
Oct 2025
Publication
The growing demand for air connectivity coupled with the forecasted increase in passengers by 2040 implies an exigency in the aviation sector to adopt sustainable approaches for net zero emission by 2050. Sustainable Aviation Fuel (SAF) is currently the most promising short-term solution; however ensuring its overall sustainability depends on reducing the life cycle carbon footprints. A key challenge prevails in hydrogen usage as a reactant for the approved ASTM routes of SAF. The processing conversion and refinement of feed entailing hydrodeoxygenation (HDO) decarboxylation hydrogenation isomerisation and hydrocracking requires substantial hydrogen input. This hydrogen is sourced either in situ or ex situ with the supply chain encompassing renewables or non-renewables origins. Addressing this hydrogen usage and recognising the emission implications thereof has therefore become a novel research priority. Aside from the preferred adoption of renewable water electrolysis to generate hydrogen other promising pathways encompass hydrothermal gasification biomass gasification (with or without carbon capture) and biomethane with steam methane reforming (with or without carbon capture) owing to the lower greenhouse emissions the convincing status of the technology readiness level and the lower acidification potential. Equally imperative are measures for reducing hydrogen demand in SAF pathways. Strategies involve identifying the appropriate catalyst (monometallic and bimetallic sulphide catalyst) increasing the catalyst life in the deoxygenation process deploying low-cost iso-propanol (hydrogen donor) developing the aerobic fermentation of sugar to 14 dimethyl cyclooctane with the intermediate formation of isoprene and advancing aqueous phase reforming or single-stage hydro processing. Other supportive alternatives include implementing the catalytic and co-pyrolysis of waste oil with solid feedstocks and selecting highly saturated feedstock. Thus future progress demands coordinated innovation and research endeavours to bolster the seamless integration of the cutting-edge hydrogen production processes with the SAF infrastructure. Rigorous technoeconomic and life cycle assessments alongside technological breakthroughs and biomass characterisation are indispensable for ensuring scalability and sustainability
Coordinated Control Strategy for Island Power Generation System with Photovoltaic, Hydrogen-Fueled Gas Turbine and Hybrid Energy Storage
Oct 2025
Publication
Marine and island power systems usually incorporate various forms of energy supply which poses challenges to the coordinated control of the system under diverse irregular and complex load operation modes. To improve the stability and self-sufficiency of island-isolated microgrids with high penetration of renewable energy this study proposes a coordinated control strategy for an island microgrid with PV HGT and HESS combining primary power allocation via low-pass filtering with a fuzzy logic-based secondary correction. The fuzzy controller dynamically adjusts power distribution based on the states of charge of the battery and supercapacitor following a set of predefined rules. A comprehensive system model is developed in Matlab R2023b integrating PV generation an electrolyzer HGT and a battery–supercapacitor HESS. Simulation results across four operational cases demonstrate that the proposed strategy reduces DC bus voltage fluctuations to a maximum of 4.71% (compared to 5.63% without correction) with stability improvements between 0.96% and 1.55%. The HESS avoids overcharging and over-discharging by initiating priority charging at low SOC levels thereby extending service life. This work provides a scalable control framework for enhancing the resilience of marine and island microgrids with high renewable energy penetration.
Analysis of Fuel Cell Electric Vehicle Performance Under Standard Electric Vehicle Driving Protocol
Nov 2025
Publication
The paper studies and analyzes electric vehicle engines powered by hydrogen under the WLTP standard driving protocol. The driving range extension is estimated using a specific protocol developed for FCEV compared with the standard value for battery electric vehicles. The driving range is extended by 10 km averaging over the four protocols with a maximum of 11.6 km for the FTP-75 and a minimum of 7.7 km for the WLTP. This driving range extension represents a 1.8% driving range improvement on average. Applying the FCEV current weight the driving range is extended to 18.9 km and 20.4 km on average when using power source energy capacity standards for BEVs and FCEVs.
Rooftop Agrivoltaic Powered Onsite Hydrogen Production for Insulated Gasochromic Smart Glazing and Hydrogen Vehicles: A Holistic Approach to Sustainable Residential Building
Nov 2025
Publication
The study focused on designing a sustainable building involving rooftop agrivoltaics advanced glazing technologies and onsite hydrogen production for a residential property in Birmingham UK where green hydrogen produced by harnessing electricity generated by agrivoltaics system on rooftop of the building is employed to change the transparency of vacuum gasochromic glazing and refuel hydrogen-powered fuel cell vehicle using storage hydrogen for a sustainable building approach. The change in the transparency of the glazing reduces the energy requirement of the building according to the occupant’s requirement and weather conditions. This research investigates the performance of various rooftop agrivoltaic systems including vertical optimal 30◦ tilt and dome setups for both monofacial and bifacial agrivoltaic consisting of tomato farming. Promising results were observed for agrivoltaic systems with consistent tomato production of 0.31 kg/m2 with varying shading experienced due to the different photovoltaic setups. Maximum electricity is produced by bifacial 30◦ with 7919 kWh though the lowest LCOE can be observed by monofacial 30◦ with £0.061/kWh. It also compares the efficiency of vacuum gasochromic windows against double glazing vacuum double glazing electrochromic and gasochromic options which can play an essential role in energy saving and reduced carbon emission. Vacuum gasochromic demonstrated the lowest U-value of 1.32 Wm2 K though it has the highest thickness with 24.6 mm. Additionally the study examines the feasibility of small-scale green hydrogen production from the electricity generated by agrivoltaics to fuel hydrogen vehicles and glazing considering the economic viability. The results suggested that the hydrogen required by the glazing accounts for 52.56 g annually and the maximum distance that can be covered theoretically is by bifacial 30◦ which is approximately 64.23 km per day. The interdisciplinary approach aims to optimise land use enhance energy efficiency and promote sustainable urban agriculture to contribute to the UK’s goal of increasing solar energy capacity and achieving net-zero emissions while addressing food security concerns. The findings of this study have potential implications for urban planning renewable energy integration especially solar and sustainable residential design.
Interleaved Parallel VDCM Improves Stability Control of Wind Power-hydrogen Coupled Integrated System
Nov 2025
Publication
Aiming at the problems of poor transient characteristics of converter output DC voltage and large DC current ripple caused by alkaline electrolyzer (AEL) switching operation in the wind power-hydrogen coupled integrated system this paper proposes an interleaved parallel VDCM control method to improve the stable operation of the system. Firstly a refined mathematical-physical model of the wind power-hydrogen coupled integrated system including HD-PMSG interleaved parallel buck and AEL is constructed. Then the VDCM control strategy is introduced into the interleaved parallel buck converter which provides reliable inertia and damping support for the output voltage of the hydrogen production system by simulating the DC motor power regulation characteristics and effectively improving the current ripple of the output current. Meanwhile the influence of rotational inertia and the damping coefficient on the dynamic stability of the system in the control strategy is analyzed based on the small signal method. Finally the proposed method is validated through MATLAB/SIMULINK simulation experiments and RCP + HIL hardware-in-the-loop experiments. The results show that the proposed method can improve the dynamic stability of the wind power-hydrogen coupled integrated system effectively.
A Pathway to Decarbonizing Cement Manufacturing via Solar-driven Green Hydrogen Systems
Nov 2025
Publication
The cement industry a foundation of infrastructure development is responsible for nearly 7 % of global CO2 emissions highlighting an urgent need for scalable decarbonization strategies. This study investigates the technoeconomic feasibility of integrating on-site solar-powered green hydrogen production into cement manufacturing processes. A mixed-integer linear programming (MILP) model optimizes the design and operation of solar photovoltaics (PV) proton exchange membrane (PEM) electrolyzer and hydrogen storage for a representative cement plant in Texas. Five hydrogen substitution scenarios (10–30 % of thermal demand) were evaluated based on net present cost (NPC) levelized cost of hydrogen (LCOH) cost of CO2 avoided and greenhouse gas (GHG) emissions reduction. Hydrogen integration up to 30 % is technically viable but economically constrained with LCOH rising non-linearly from $58.7 to $95.3 GJ− 1 due to escalating component costs. Environmentally a 30 % hydrogen share could reduce total U.S. cement sector emissions by 22 %. While significant this confirms at present the solar-driven hydrogen serves as a partial solution rather than a standalone pathway to deep decarbonization suggesting it must complement other strategies like carbon capture electrification and other complementary technologies. The economic viability of this approach is entirely contingent on financial incentives as the investment tax credits of 80 % or higher are essential to enable cost parity with fossil fuels. This work provides a comprehensive techno-economic and environmental framework concluding immense economic barriers and that aggressive policy support is indispensable for enabling the transition to low-carbon cement manufacturing.
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