Production & Supply Chain

Population growth and the expansion of industries have increased energy demand and the use of fossil fuels as an energy source resulting in release of greenhouse gases (GHG) and increased air pollution. Countries are therefore looking for alternatives to fossil fuels for energy generation. Using hydrogen as an energy carrier is one of the most promising alternatives to replace fossil fuels in electricity generation. It is therefore essential to know how hydrogen is produced. Hydrogen can be produced by splitting the water molecules in an electrolyser using the abondand water resources which are covering around ⅔ of the Earth's surface. Electrolysers however require high-quality water with conductivity in the range of 0.1–1 μS/cm. In January 2018 there were 184 offshore oil and gas rigs in the North Sea which may be excellent sites for hydrogen production from seawater. The hydrogen production process reported in this paper is based on a proton exchange membrane (PEM) electrolyser with an input flow rate of 300 L/h. A financially optimal system for producing demineralized water from seawater with conductivity in the range of 0.1–1 μS/cm as the input for electrolyser by WAVE (Water Application Value Engine) design software was studied. The costs of producing hydrogen using the optimised system was calculated to be US$3.51/kg H2. The best option for low-cost power generation using renewable resources such as photovoltaic (PV) devices wind turbines as well as electricity from the grid was assessed considering the location of the case considered. All calculations were based on assumption of existing cable from the grid to the offshore meaning that the cost of cables and distribution infrastructure were not considered. Models were created using HOMER Pro (Hybrid Optimisation of Multiple Energy Resources) software to optimise the microgrids and the distributed energy resources under the assumption of a nominal discount rate inflation rate project lifetime and CO2 tax in Norway. Eight different scenarios were examined using HOMER Pro and the main findings being as follows:<br/>The cost of producing water with quality required by the electrolyser is low compared with the cost of electricity for operation of the electrolyser and therefore has little effect on the total cost of hydrogen production (less than 1%).<br/>The optimal solution was shown to be electricity from the grid which has the lowest levelised cost of energy (LCOE) of the options considered. The hydrogen production cost using electricity from the grid was about US$ 5/kg H2.<br/>Grid based electricity resulted in the lowest hydrogen production cost even when costs for CO2 emissions in Norway that will start to apply in 2025 was considered being approximately US$7.7/kg H2.<br/>From economical point of view wind energy was found to be a more economical than solar.

Hydrogen technologies have received increased attention in research and development to foster the shift towards carbon-neutral energy systems. Depending on the specific production techniques transportation concepts and application areas hydrogen supply chains (HSCs) can be anything from part of the energy transition problem to part of the solution: Even more than battery-driven electric mobility hydrogen is a polyvalent technology and can be used in very different contexts with specific positive or negative sustainability impacts. Thus a detailed sustainability evaluation is crucial for decision making in the context of hydrogen technology and its diverse application fields. This article provides a comprehensive structured literature review in the context of HSCs along the triple bottom line dimensions of environmental economic and social sustainability analyzing a total of 288 research papers. As a result we identify research gaps mostly regarding social sustainability and the supply chain stages of hydrogen distribution and usage. We suggest further research to concentrate on these gaps thus strengthening our understanding of comprehensive sustainability evaluations for HSCs especially in social sustainability evaluation. In addition we provide an additional approach for discussion by adding literature review results from neighboring fields highlighting the joint challenges and insights regarding sustainability evaluation.

Industrial hydrogen production via alkaline water electrolysis (AEL) is a mature hydrogen production method. One argument in favor of AEL when supplied with renewable energy is its environmental superiority against conventional fossil-based hydrogen production. However today electricity from the national grid is widely utilized for industrial applications of AEL. Also the ban on asbestos membranes led to a change in performance patterns making a detailed assessment necessary. This study presents a comparative Life Cycle Assessment (LCA) using the GaBi software (version 6.115 thinkstep Leinfelden-Echterdingen Germany) revealing inventory data and environmental impacts for industrial hydrogen production by latest AELs (6 MW Zirfon membranes) in three different countries (Austria Germany and Spain) with corresponding grid mixes. The results confirm the dependence of most environmental effects from the operation phase and specifically the site-dependent electricity mix. Construction of system components and the replacement of cell stacks make a minor contribution. At present considering the three countries AEL can be operated in the most environmentally friendly fashion in Austria. Concerning the construction of AEL plants the materials nickel and polytetrafluoroethylene in particular used for cell manufacturing revealed significant contributions to the environmental burden.

Hydrogen is a clean fuel for transportation and energy storage. It has several attractive features including a higher energy content by weight use in fuel cells that produces only water as a by-product storage in small and large quantities by various methods and established transportation and infrastructures. A hydrogen economy consists of three steps i.e. hydrogen production storage and applications. All three steps involved in a hydrogen economy can be divided into catalytic and non-catalytic approaches. For catalytic processes the efficiency highly depends on the type and physico-chemical characteristics of the catalysts. Therefore for the improvement of these catalytic processes the development of highly efficient and stable catalysts is highly required.

In the future hydrogen (H2) will play a significant role in the sustainable supply of energy and raw materials to various sectors. Therefore the electrolysis of water required for industrial‐ scale H2 production represents a key component in the generation of renewable electricity. Within the scope of fundamental research work on cell components for polymer electrolyte membrane (PEM) electrolyzers and application‐oriented living labs an MW electrolysis system was used to further improve industrial‐scale electrolysis technology in terms of its basic structure and systems‐ related integration. The planning of this work as well as the analytical and technical approaches taken along with the essential results of research and development are presented herein. The focus of this study is the test facility for a megawatt PEM electrolysis stack with the presentation of the design processing and assembly of the main components of the facility and stack.

The production of “green hydrogen” is currently one of the hottest topics in the field of renewable energy systems research. Hydrogen storage is also becoming more and more attractive as a flexible solution to mitigate the power fluctuations of solar energy systems. The most promising technology for electricity-to-hydrogen conversion and vice versa is the reversible solid-oxide cell (SOC). This device is still very expensive but it exhibits excellent performance under dynamic operating conditions compared to the competing devices. This work presents the dynamic simulation of a prototypal renewable plant combining a 50 kW photovoltaic (PV) field with a 50 kW solid-oxide electrolyzer cell (SOEC) and a compressed hydrogen tank. The electricity is used to meet the energy demand of a dwelling located in the area of Campi Flegrei (Naples). The SOC efficiency is simulated by developing a mathematical model in MATLAB®. The model also calculates the cell operating temperature as a function of the input current. Once the optimal values of the operating parameters of the SOC are calculated the model is integrated in the transient system simulation tool (TRNSYS) for dynamic analysis. Furthermore this work presents a parametric analysis of the hydrogen storage system (HSS). The results of the energy and environmental analyses show that the proposed system can reach a primary energy saving by 70% and an amount of saved CO2 of 28 tons/year. Some possible future market scenarios are considered for the economic analysis. In the most realistic case the optimal configuration shows a simple pay back lower than 10 years and a profit index of 46%.

In the future the world may have large stranded resources of low-cost wind and solar electricity. Renewable electricity production does not match demand and production is far from major cities. The coupling of nuclear energy with renewables may enable full utilization of nuclear and renewable facilities to meet local electricity demands and export pipeline hydrogen for liquid fuels fertilizer and metals production. Renewables would produce electricity at full capacity in large quantities. The base-load nuclear plants would match electricity production with demand by varying the steam used for electricity versus hydrogen production. High-temperature electrolysis (HTE) would produce hydrogen from water using (a) steam from nuclear plants and (b) electricity from nuclear plants and renewables. During times of peak electricity demand the HTE cells would operate in reverse fuel cell mode to produce power substituting for gas turbines that are used for very few hours per year and that thus have very high electricity costs. The important net hydrogen production would be shipped by pipeline to customers. Local hydrogen storage would enable full utilization of long-distance pipeline capacity with variable production. The electricity and hydrogen production were simulated with real load and wind data to understand under what conditions such systems are economic. The parametric case study uses a wind-nuclear system in North Dakota with hydrogen exported to the Chicago refinery market. North Dakota has some of the best wind conditions in the United States and thus potentially low-cost wind. The methodology allows assessments with different economic and technical assumptions - including what electrolyzer characteristics are most important for economic viability.

Gasification of municipal solid waste (MSW) with subsequent utilization of syngas in gas engines/turbines and solid oxide fuel cells can substantially increase the power generation of waste-to-energy facilities and optimize the utilization of wastes as a sustainable energy resources. However purification of syngas to remove multiple impurities such as particulates tar HCl alkali chlorides and sulfur species is required. This study investigates the feasibility of high temperature purification of syngas from MSW gasification with the focus on catalytic tar reforming and desulfurization. Syngas produced from a downdraft fixed-bed gasifier is purified by a multi-stage system. The system comprises of a fluidized-bed catalytic tar reformer a filter for particulates and a fixed-bed reactor for dechlorination and then desulfurization with overall downward cascading of the operating temperatures throughout the system. Novel nano-structured nickel catalyst supported on alumina and regenerable Ni-Zn desulfurization sorbent loaded on honeycomb are synthesized. Complementary sampling and analysis methods are applied to quantify the impurities and determine their distribution at different stages. Experimental and thermodynamic modeling results are compared to determine the kinetic constraints in the integrated system. The hot purification system demonstrates up to 90% of tar and sulfur removal efficiency increased total syngas yield (14%) and improved cold gas efficiency (12%). The treated syngas is potentially applicable in gas engines/turbines and solid oxide fuel cells based on the dew points and concentration limits of the remaining tar compounds. Reforming of raw syngas by nickel catalyst for over 20 h on stream shows strong resistance to deactivation. Desulfurization of syngas from MSW gasification containing significantly higher proportion of carbonyl sulfide than hydrogen sulfide traces of tar and hydrogen chloride demonstrates high performance of Ni-Zn sorbents.

The WGS reaction is an exothermic reaction between carbon monoxide and steam to form carbon dioxide and hydrogen. This reaction which has been used industrially for more than 100 years has recently received a great deal of attention from researchers as one of the ways to produce environmentally acceptable hydrogen from fossil fuels in large quantities. For the application of this reaction on an industrial scale the key is choosing the optimal catalysts that can ensure high CO conversion and have a long lifetime under industrial conditions. Therefore new types of catalysts are being developed that meet these requirements better than the Fe- and Cu-based catalysts commonly used in the past. The WGSR on a commercial nickel-based catalyst and a laboratory-prepared copper and cobalt-based catalyst was tested in a laboratory apparatus set up at the University of Chemistry and Technology Prague. The best performance of the laboratory-prepared catalyst was observed for the catalyst with a Cu content of 14.8 wt% and activated in a hydrogen atmosphere. The laboratory-prepared Co-based catalyst showed good WGSR activity in the temperature range of 200–450 ◦C although this was always inferior to that of the Cu-based catalyst. When subjected to the feed gas containing 0.4 mole% H2S the Co-based catalyst showed good resistance to sulphur poisoning. Therefore Co-based catalysts can be considered good sulphur-tolerant intermediate temperature WGSR catalysts.

Hydrogen fuel production from methane cracking is a cleaner process compared to steam methane reforming due to zero greenhouse gas emissions. Carbon black that is co-produced is valuable and can be marketed to other industries. As this is a high-temperature process using solar energy can further improve its sustainability. In this study an integrated solar methane cracking system is proposed and the efficient utilization of the hydrogen and carbon products is explored. The carbon by-product is used in a direct carbon fuel cell and oxy- combustion. These processes eliminate the need for carbon capture technologies as they produce pure CO2 exhaust streams. The CO2 produced from the systems is used for enhanced oil recovery to produce crude oil. The produced turquoise hydrogen is liquified to make it suitable for exportation. The process is simulated on Aspen Plus® and its energy and exergy efficiencies are evaluated by carrying out a detailed thermodynamic analysis. A reservoir simulation is used to study the amount of oil that can be produced using the captured CO2. The overall system is studied for oil production over 20 years and energy and exergy of efficiencies 42.18% and 40.18% respectively were found. Enhanced oil recovery improves the recovery rate from 24.8% to 64.3%.