Applications & Pathways
Total Cost of Ownership Analysis of Fuel Cell Electric Bus with Different Hydrogen Supply Alternatives
Dec 2023
Publication
In the transition to sustainable public transportation with zero-emission buses hydrogen fuel cell electric buses have emerged as a promising alternative to traditional diesel buses. However assessing their economic viability is crucial for widespread adoption. This study carries out a comprehensive examination encompassing both sensitivity and probabilistic analyses to assess the total cost of ownership (TCO) for the bus fleet and its corresponding infrastructure. It considers various hydrogen supply options encompassing on-site electrolysis on-site steam methane reforming and off-site hydrogen procurement with both gaseous and liquid delivery methods. The analysis covers critical cost elements encompassing bus acquisition costs infrastructure capital expenses and operational and maintenance costs for both buses and infrastructure. This paper conducted two distinct case studies: one involving a current small bus fleet of five buses and another focusing on a larger fleet set to launch in 2028. For the current small fleet the off-site gray hydrogen purchase with a gaseous delivery option is the most cost-effective among hydrogen alternatives but it still incurs a 26.97% higher TCO compared to diesel buses. However in the case of the expanded 2028 fleet the steam methane-reforming method without carbon capture emerges as the most likely option to attain the lowest TCO with a high probability of 99.5%. Additionally carbon emission costs were incorporated in response to the growing emphasis on environmental sustainability. The findings indicate that although diesel buses currently represent the most economical option in terms of TCO for the existing small fleet steam methane reforming with carbon capture presents a 69.2% likelihood of being the most cost-effective solution suggesting it is a strong candidate for cost efficiency for the expanded 2028 fleet. Notably substantial investments are required to increase renewable energy integration in the power grid and to enhance electrolyzer efficiency. These improvements are essential to make the electrolyzer a more competitive alternative to steam methane reforming. Overall the findings in this paper underscore the substantial impact of the hydrogen supply chain and carbon emission costs on the TCO of zero-emission buses.
Mitigating Emissions in the Global Steel Industry: Representing CCS and Hydrogen Technologies in Integrated Assessment Modelling
Dec 2023
Publication
We conduct a techno-economic assessment of two low-emissions steel production technologies and evaluate their deployment in emissions mitigation scenarios utilizing the MIT Economic Projection and Policy Analysis (EPPA) model. Specifically we assess direct reduced iron-electric arc furnace with carbon capture and storage (DRI-EAF with CCS) and H2-based direct reduced iron-electric arc furnace (H2 DRI-EAF) which utilizes low carbon hydrogen to reduce CO2 emissions. Our techno-economic analysis based on the current state of technologies found that DRI-EAF with CCS increased costs ~7% relative to the conventional steel technology. H2 DRI-EAF increased costs by ~18% when utilizing Blue hydrogen and ~79% when using Green hydrogen. The exact pathways for hydrogen production in different world regions including the extent of CCS and hydrogen deployment in steelmaking are highly speculative at this point. In illustrative scenarios using EPPA we find that using base cost assumptions switching from BF-BOF to DRI-EAF or scrap EAF can provide significant emissions mitigation within steelmaking. With further reductions in the cost of advanced steelmaking we find a greater role for DRI-EAF with CCS whereas reductions in both the cost of advanced steelmaking and hydrogen production lead to a greater role for H2 DRI-EAF. Our findings can be used to help decision-makers assess various decarbonization options and design economically efficient pathways to reduce emissions in the steel industry. Our cost evaluation can also be used to inform other energy-economic and integrated assessment models designed to provide insights about future decarbonization pathways.
Thermodynamic Modelling and Optimisation of a Green Hydrogen-blended Syngas-fueled Integrated PV-SOFC System
Sep 2023
Publication
Developing an effective energy transition roadmap is crucial in the face of global commitments to achieve net zero emissions. While renewable power generation systems are expanding challenges such as curtailments and grid constraints can lead to energy loss. To address this surplus electricity can be converted into green hydrogen serving as a key component in the energy transition. This research explores the use of renewable solar energy for powering a proton exchange membrane electrolyser to produce green hydrogen while a downdraft gasifier fed by municipal solid waste generates hydrogen-enriched syngas. The blended fuel is then used to feed a Solid Oxide Fuel Cell (SOFC) system. The study investigates the impact of hydrogen content on the performance of the fuel cell-based power plant from thermodynamics and exergoeconomic perspectives. Multiobjective optimisation using a genetic algorithm identifies optimal operating conditions for the system. Results show that blending hydrogen with syngas increases combined heat and power efficiency by up to 3% but also raises remarkably the unit product cost and reduces carbon dioxide emissions. Therefore the optimal values for hydrogen content current density temperatures and other parameters are determined. These findings contribute to the design and operation of an efficient and sustainable energy generation system.
Economic Analysis of a Photovoltaic Hydrogen Refueling Station Based on Hydrogen Load
Sep 2023
Publication
With the goal of achieving “carbon peak in 2030 and carbon neutrality in 2060” as clearly proposed by China the transportation sector will face long–term pressure on carbon emissions and the application of hydrogen fuel cell vehicles will usher in a rapid growth period. However true “zero carbon” emissions cannot be separated from “green hydrogen”. Therefore it is of practical significance to explore the feasibility of renewable energy hydrogen production in the context of hydrogen refueling stations especially photovoltaic hydrogen production which is applied to hydrogen refueling stations (hereinafter referred to “photovoltaic hydrogen refueling stations”). This paper takes a hydrogen refueling station in Shanghai with a supply capacity of 500 kg/day as the research object. Based on a characteristic analysis of the hydrogen demand of the hydrogen refueling station throughout the day this paper studies and analyzes the system configuration operation strategy environmental effects and economics of the photovoltaic hydrogen refueling station. It is estimated that when the hydrogen price is no less than 6.23 USD the photovoltaic hydrogen refueling station has good economic benefits. Additionally compared with the conventional hydrogen refueling station it can reduce carbon emissions by approximately 1237.28 tons per year with good environmental benefits.
Environmental Assessment of Replacing Fossil Fuels with Hydrogen for Motorised Equipment in the Mining Sector
Nov 2023
Publication
To achieve the European milestone of climate neutrality by 2050 the decarbonisation of energy-intensive industries is essential. In 2022 global energy-related CO2 emissions increased by 0.9% or 321 Mt reaching a peak of over 36.8 Gt. A large amount of these emissions is the result of fossil fuel usage in the motorised equipment used in mining. Heavy diesel vehicles like excavators wheel loaders and dozers are responsible for an estimated annual CO2 emissions of 400 Mt of CO2 accounting for approximately 1.1% of global CO2 emissions. In addition exhaust gases of CO2 and NOx endanger the personnel’s health in all mining operations especially in underground environments. To tackle these environmental concerns and enhance environmental health extractive industries are focusing on replacing fossil fuels with alternative fuels of low or zero CO2 emissions. In mining the International Council on Mining and Metals has committed to achieving net zero emissions by 2050 or earlier. Of the various alternative fuels hydrogen (H2 ) has seen a considerable rise in popularity in recent years as H2 combustion accounts for zero CO2 emissions due to the lack of carbon in the burning process. When combusted with pure oxygen it also accounts for zero NOx formation and near-zero emissions overall. To this end this study aims to examine the overall environmental performance of H2 -powered motorised equipment compared to conventional fossil fuel-powered equipment through Life Cycle Assessment. The assessment was conducted using the commercial software Sphera LCA for Experts following the conventionally used framework established by ISO 14040:2006 and 14044:2006/A1:2018 and the International Life Cycle Data Handbook consisting of (1) the goal and scope definition (2) the Life Cycle Inventory (LCI) preparation (3) the Life Cycle Impact Assessment (LCIA) and (4) the interpretation of the results. The results will offer an overview to support decision-makers in the sector.
Integration of a Multi-Stack Fuel Cell System in Microgrids: A Solution Based on Model Predictive Control
Sep 2020
Publication
This paper proposes a multi-objective model predictive control (MPC) designed for the power management of a multi-stack fuel cell (FC) system integrated into a renewable sources-based microgrid. The main advantage of MPC is the fact that it allows the current timeslot to be optimized while taking future timeslots into account. The multi-objective function solves the problem related to the power dispatch at time that includes criteria to reduce the multi-stack FC degradation operating and maintenance costs as well as hydrogen consumption. Regarding the scientific literature the novelty of this paper lies in the proposal of a generalized MPC controller for a multi-stack FC that can be used independently of the number of stacks that make it up. Although all the stacks that make up the modular FC system are identical their levels of degradation in general will not be. Thus over time each stack can present a different behavior. Therefore the power control strategy cannot be based on an equal distribution according to the nominal power of each stack. On the contrary the control algorithm should take advantage of the characteristics of the multi-stack FC concept distributing operation across all the stacks regarding their capacity to produce power/energy and optimizing the overall performance.
Alternative-energy-vehicles Deployment Delivers Climate, Air Quality, and Health Co-benefits when Coupled with Decarbonizing Power Generation in China
Aug 2021
Publication
China is the world’s largest carbon emitter and suffers from severe air pollution which results in approximately one million premature deaths/year. Alternative energy vehicles (AEVs) (electric hydrogen fuel cell and natural gas vehicles) can reduce carbon emissions and improve air quality. However climate air quality and health benefits of AEVs powered with deeply decarbonized power generation are poorly quantified. Here we quantitatively estimate the air quality health carbon emission and economic benefits of replacing internal combustion engine vehicles with various AEVs. We find co-benefits increase dramatically as the electricity grid decarbonizes and hydrogen is produced from non-fossil fuels. Relative to 2015 a conversion to AEVs using largely non-fossil power can reduce air pollution and associated premature mortalities and years of life lost by 329000 persons/year and 1611000 life years/year. Thus maximizing climate air quality and health benefits of AEV deployment in China requires rapid decarbonization of the power system.
Combustion Characterization in a Diffusive Gas Turbine Burner for Hydrogen-Compliant Applications
Jun 2022
Publication
The target of net-zero emissions set by the 2015 Paris Agreement has strongly commissioned the energy production sector to promote decarbonization renewable sources exploitation and systems efficiency. In this framework the utilization of hydrogen as a long-term energy carrier has great potential. This paper is concerned with the combustion characterization in a non-premixed gas turbine burner originally designed for natural gas when it is fed with NG-H2 blends featuring hydrogen content from 0 to 50% in volume. The final aim is to retrofit a 40 MW gas turbine. Starting from the operational data of the engine a CFD model of the steady-state combustion process has been developed with reference to the base load NG conditions by reducing the fuel mass-flow rate by up to 17% to target the baseline turbine inlet temperature. When the fuel is blended with hydrogen for a given temperature at turbine inlet an increase in the peak temperature up to 800 K is obtained if no countermeasures are taken. Furthermore the flame results are more intense and closer to the injector in the case of hydrogen blending. The results of this work hint at the necessity of carefully analyzing the possible NOx compensation strategies as well as the increased thermal stresses on the injector.
A Hydrogen Fuelled LH2 Tanker Ship Design
May 2021
Publication
This study provides a detailed philosophical view and evaluation of a viable design for a large liquid hydrogen tanker fuelled by liquid hydrogen. Established methods for determining tank sizing ship stability and ship characteristics were used to evaluate the preliminary design and performance of the liquefied hydrogen tanker named ‘JAMILA’ designed specifically to transport liquid hydrogen. JAMILA is designed around four large liquid hydrogen tanks with a total capacity of ∼280000 m3 and uses the boil-off gas for propulsion for the loaded leg of the journey. The ship is 370 m long 75 m wide and draws 10.012 m at full load. It has a fully loaded displacement tonnage of 232000 tonnes to carry 20000 tonnes of hydrogen. Its propulsion system contains a combined-cycle gas turbine of approximately 50 MW. The volume of the hydrogen cargo pressurised to 0.5 MPa primarily determines the size and displacement of the ship.
A Review of Hydrogen Direct Injection for Internal Combustion Engines: Towards Carbon-Free Combustion
Nov 2018
Publication
A paradigm shift towards the utilization of carbon-neutral and low emission fuels is necessary in the internal combustion engine industry to fulfil the carbon emission goals and future legislation requirements in many countries. Hydrogen as an energy carrier and main fuel is a promising option due to its carbon-free content wide flammability limits and fast flame speeds. For spark-ignited internal combustion engines utilizing hydrogen direct injection has been proven to achieve high engine power output and efficiency with low emissions. This review provides an overview of the current development and understanding of hydrogen use in internal combustion engines that are usually spark ignited under various engine operation modes and strategies. This paper then proceeds to outline the gaps in current knowledge along with better potential strategies and technologies that could be adopted for hydrogen direct injection in the context of compression-ignition engine applications—topics that have not yet been extensively explored to date with hydrogen but have shown advantages with compressed natural gas.
Thermal Management System Architecture for Hydrogen-Powered Propulsion Technologies: Practices, Thematic Clusters, System Architectures, Future Challenges, and Opportunities
Jan 2022
Publication
The thermal management system architectures proposed for hydrogen-powered propulsion technologies are critically reviewed and assessed. The objectives of this paper are to determine the system-level shortcomings and to recognise the remaining challenges and research questions that need to be sorted out in order to enable this disruptive technology to be utilised by propulsion system manufacturers. Initially a scientometrics based co-word analysis is conducted to identify the milestones for the literature review as well as to illustrate the connections between relevant ideas by considering the patterns of co-occurrence of words. Then a historical review of the proposed embodiments and concepts dating back to 1995 is followed. Next feasible thermal management system architectures are classified into three distinct classes and its components are discussed. These architectures are further extended and adapted for the application of hydrogen-powered fuel cells in aviation. This climaxes with the assessment of the available evidence to verify the reasons why no hydrogen-powered propulsion thermal management system architecture has yet been approved for commercial production. Finally the remaining research challenges are identified through a systematic examination of the critical areas in thermal management systems for application to hydrogen-powered air vehicles’ engine cooling. The proposed solutions are discussed from weight cost complexity and impact points of view by a system-level assessment of the critical areas in the field.
A Novel Remaining Useful Life Prediction Method for Hydrogen Fuel Cells Based on the Gated Recurrent Unit Neural Network
Jan 2022
Publication
The remaining useful life (RUL) prediction for hydrogen fuel cells is an important part of its prognostics and health management (PHM). Artificial neural networks (ANNs) are proven to be very effective in RUL prediction as they do not need to understand the failure mechanisms behind hydrogen fuel cells. A novel RUL prediction method for hydrogen fuel cells based on the gated recurrent unit ANN is proposed in this paper. Firstly the data were preprocessed to remove outliers and noises. Secondly the performance of different neural networks is compared including the back propagation neural network (BPNN) the long short-term memory (LSTM) network and the gated recurrent unit (GRU) network. According to our proposed method based on GRU the root mean square error was 0.0026 the mean absolute percentage error was 0.0038 and the coefficient of determination was 0.9891 for the data from the challenge datasets provided by FCLAB Research Federation when the prediction starting point was 650 h. Compared with the other RUL prediction methods based on the BPNN and the LSTM our prediction method is better in both prediction accuracy and convergence rate.
New Combustion Modelling Approach for Methane-Hydrogen Fueled Engines Using Machine Learning and Engine Virtualization
Oct 2021
Publication
The achievement of a carbon-free emissions economy is one of the main goals to reduce climate change and its negative effects. Scientists and technological improvements have followed this trend improving efficiency and reducing carbon and other compounds that foment climate change. Since the main contributor of these emissions is transportation detaching this sector from fossil fuels is a necessary step towards an environmentally friendly future. Therefore an evaluation of alternative fuels will be needed to find a suitable replacement for traditional fossil-based fuels. In this scenario hydrogen appears as a possible solution. However the existence of the drawbacks associated with the application of H2 -ICE redirects the solution to dual-fuel strategies which consist of mixing different fuels to reduce negative aspects of their separate use while enhancing the benefits. In this work a new combustion modelling approach based on machine learning (ML) modeling is proposed for predicting the burning rate of different mixtures of methane (CH4 ) and hydrogen (H2). Laminar flame speed calculations have been performed to train the ML model finding a faster way to obtain good results in comparison with actual models applied to SI engines in the virtual engine model framework.
Porosity and Thickness Effect of Pd–Cu–Si Metallic Glasses on Electrocatalytic Hydrogen Production and Storage
Aug 2021
Publication
This contribution places emphasis on tuning pore architecture and film thickness of mesoporous Pd–Cu–Si thin films sputtered on Si/SiO2 substrates for enhanced electrocatalytic and hydrogen sorption/desorption activity and their comparison with the state-of-the-art thin film electrocatalysts. Small Tafel slope of 43 mV dec–1 for 1250 nm thick coatings with 2 µm diameter pores with 4.2 µm interspacing (H2) electrocatalyst with comparable hydrogen overpotentials to the literature suggests its use for standard fuel cells. The largest hydrogen sorption has been attained for the 250 nm thick electrocatalyst on 5 µm pore diameter and 12 µm interspacing (2189 µC cm–2 per CV cycle) making it possible for rapid storage systems. Moreover the charge transfer resistance described by an equivalent circuit model has an excellent correlation with Tafel slopes. Along with its very low Tafel slope of 42 mV dec–1 10 nm thick H2 pore design electrocatalyst has the highest capacitive response of ∼0.001 S sn cm–2 and is promising to be used as a nano-charger and hydrogen sensor.
Fundamentals, Materials, and Machine Learning of Polymer Electrolyte Membrane Fuel Cell Technology
Jun 2020
Publication
Polymer electrolyte membrane (PEM) fuel cells are electrochemical devices that directly convert the chemical energy stored in fuel into electrical energy with a practical conversion efficiency as high as 65%. In the past years significant progress has been made in PEM fuel cell commercialization. By 2019 there were over 19000 fuel cell electric vehicles (FCEV) and 340 hydrogen refueling stations (HRF) in the U.S. (~8000 and 44 respectively) Japan (~3600 and 112 respectively) South Korea (~5000 and 34 respectively) Europe (~2500 and 140 respectively) and China (~110 and 12 respectively). Japan South Korea and China plan to build approximately 3000 HRF stations by 2030. In 2019 Hyundai Nexo and Toyota Mirai accounted for approximately 63% and 32% of the total sales with a driving range of 380 and 312 miles and a mile per gallon (MPGe) of 65 and 67 respectively. Fundamentals of PEM fuel cells play a crucial role in the technological advancement to improve fuel cell performance/durability and reduce cost. Several key aspects for fuel cell design operational control and material development such as durability electrocatalyst materials water and thermal management dynamic operation and cold start are briefly explained in this work. Machine learning and artificial intelligence (AI) have received increasing attention in material/energy development. This review also discusses their applications and potential in the development of fundamental knowledge and correlations material selection and improvement cell design and optimization system control power management and monitoring of operation health for PEM fuel cells along with main physics in PEM fuel cells for physics-informed machine learning. The objective of this review is three fold: (1) to present the most recent status of PEM fuel cell applications in the portable stationary and transportation sectors; (2) to describe the important fundamentals for the further advancement of fuel cell technology in terms of design and control optimization cost reduction and durability improvement; and (3) to explain machine learning physics-informed deep learning and AI methods and describe their significant potentials in PEM fuel cell research and development (R&D).
Hydrogen vs. Batteries: Comparative Safety Assessments for a High-Speed Passenger Ferry
Mar 2022
Publication
Batteries and hydrogen constitute two of the most promising solutions for decarbonising international shipping. This paper presents the comparison between a battery and a proton-exchange membrane hydrogen fuel cell version of a high-speed catamaran ferry with a main focus on safety. The systems required for each version are properly sized and fitted according to the applicable rules and their impact on the overall design is discussed. Hazards for both designs were identified; frequency and consequence indexes for them were input qualitatively following Novel Technology Qualification and SOLAS Alternative Designs and Arrangements while certain risk control options were proposed in order to reduce the risks of the most concerned accidental events. The highest ranked risks were analysed by quantitative risk assessments in PyroSim software. The gas dispersion analysis performed for the hydrogen version indicated that it is crucial for the leakage in the fuel cell room to be stopped within 1 s after being detected to prevent the formation of explosive masses under full pipe rupture of 33 mm diameter even with 120 air changes per hour. For the battery version the smoke/fire simulation in the battery room indicated that the firefighting system could achieve a 30% reduction in fire duration with firedoors closed and ventilation shut compared to the scenario without a firefighting system.
Opportunities for Low-carbon Generation and Storage Technologies to Decarbonise the Future Power System
Feb 2023
Publication
Alternatives to cope with the challenges of high shares of renewable electricity in power systems have been addressed from different approaches such as energy storage and low-carbon technologies. However no model has previously considered integrating these technologies under stability requirements and different climate conditions. In this study we include this approach to analyse the role of new technologies to decarbonise the power system. The Spanish power system is modelled to provide insights for future applications in other regions. After including storage and low-carbon technologies (currently available and under development) batteries and hydrogen fuel cells have low penetration and the derived emission reduction is negligible in all scenarios. Compressed air storage would have a limited role in the short term but its performance improves in the long term. Flexible generation technologies based on hydrogen turbines and long-duration storage would allow the greatest decarbonisation providing stability and covering up to 11–14 % of demand in the short and long term. The hydrogen storage requirement is equivalent to 18 days of average demand (well below the theoretical storage potential in the region). When these solutions are considered decarbonising the electricity system (achieving Paris targets) is possible without a significant increase in system costs (< € 114/MWh).
Optimal Energy Management in a Standalone Microgrid, with Photovoltaic Generation, Short-Term Storage, and Hydrogen Production
Mar 2020
Publication
This paper addresses the energy management of a standalone renewable energy system. The system is configured as a microgrid including photovoltaic generation a lead-acid battery as a short term energy storage system hydrogen production and several loads. In this microgrid an energy management strategy has been incorporated that pursues several objectives. On the one hand it aims to minimize the amount of energy cycled in the battery in order to reduce the associated losses and battery size. On the other hand it seeks to take advantage of the long-term surplus energy producing hydrogen and extracting it from the system to be used in a fuel cell hybrid electric vehicle. A crucial factor in this approach is to accommodate the energy consumption to the energy demand and to achieve this a model predictive control (MPC) scheme is proposed. In this context proper models for solar estimation hydrogen production and battery energy storage will be presented. Moreover the controller is capable of advancing or delaying the deferrable loads from its prescheduled time. As a result a stable and efficient supply with a relatively small battery is obtained. Finally the proposed control scheme has been validated on a real case scenario.
Study of Heat Loss Mechanism in Argon-circulated Hydrogen Engine Combustion Chamber Wall Surface Conditions
Jul 2022
Publication
Hydrogen fuel in internal combustion engine gives a very big advantage to the transportation sector especially in solving the greenhouse emission problem. However there are only few research discovered the ability of argon as a working gas in hydrogen combustion in internal combustion engine. The high temperature rises from the argon compression tend to result in heat loss problem. This research aims to study the heat loss mechanism on wall surface condition in the combustion chamber. Experiments were conducted to study the effects of different heat flux sensor locations and the effect of ignition delay on heat flux. Local heat flux measurement was collected and images were observed using high speed shadowgraph images. The ignition delay that occurred near the combustion wall will result in larger heat loss throughout the combustion process. Higher ambient pressure results in a bigger amount of heat flux value. Other fundamental characteristics were obtained and discussed which may help in contributing the local heat loss data of an argon-circulated hydrogen engine in future engine operation.
Hydrogen-powered Aviation: A Fact-based Study of Hydrogen Technology, Economics, and Climate Impact by 2050
Jul 2020
Publication
This report assesses the potential of hydrogen (H2) propulsion to reduce aviation’s climate impact. To reduce climate impact the industry will have to introduce further levers such as radically new technology significantly scale sustainable aviation fuels (SAF) such as synthetic fuel (synfuel) temporarily rely on offsets in large quantities or rely on a combination thereof. H2 propulsion is one such technology and this report assesses its potential in aviation. Developed with input from leading companies and research institutes it projects the technological development of H2 combustion and fuel cell-powered propulsion evaluates their technical and economic feasibility compares them to synfuel and considers implications on aircraft design airport infrastructure and fuel supply chains.
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