Production & Supply Chain
Hybrid Hydrogen PEM Fuel Cell and Batteries Without DC–DC Converter
Sep 2013
Publication
Concerns about greenhouse gases as well as the price and security of oil supply have acted as a spur to sustainable automobile development. The hydrogen fuel cells electric vehicle (HFCEV) is generally recognised by leading automobile manufacturers and scientists as one of the optimum technologies for long-term future low carbon vehicle. In a typical HFCEV power train a DC–DC converter is required to balance the voltage difference between the fuel cells (FCs) stack and batteries. However research shows that a considerable amount of energy generated by the hydrogen FCs stack is deplete during this conversion process as heat. This experiment aims to improve the power train efficiency by eliminating the DC–DC converter by finding the best combination of FC stack and batteries matching the size and capacity of the electrical components.
Autonomous Hydrogen Production for Proton Exchange Membrane Fuel Cells PEMFC
Apr 2020
Publication
This paper focuses on hydrogen production for green mobility applications (other applications are currently under investigation). Firstly a brief state of the art of hydrogen generation by hydrolysis with magnesium is shown. The hydrolysis performance of Magnesium powder ball–milled along with different additives (graphite and transition metals TM = Ni Fe and Al) is taken for comparison. The best performance was observed with Mg–10 wt.% g mixtures (95% of theoretical hydrogen generation yield in about 3 min). An efficient solution to control this hydrolysis reaction is proposed to produce hydrogen on demand and to feed a PEM fuel cell. Tests on a bench fitted with a 100 W Proton Exchange Membrane (PEM) fuel cell have demonstrated the technological potential of this solution for electric assistance applications in the field of light mobility.
Recent Development of Biomass Gasification for H2 Rich Gas Production
Mar 2022
Publication
Biomass gasification for hydrogen (H2) production provides outstanding advantages in terms of renewable energy resources carbon neutral high efficiency and environmental benefits. However the factors influencing H2 production from biomass gasification are complex which makes determining the optimal operating conditions challenging. Biomass gasification also poses challenges owing to the high associated tar content and low gas yield which need to be overcome. This review summarizes the influence of the gasification parameters on H2 production. Catalytic gasification technology and some of the latest catalysts such as composites and special structure catalysts are also summarized herein based on the requirements of high-purity H2 production. Moreover novel technologies such as staged gasification chemical looping gasification and adsorption-enhanced reforming for producing H2 rich gas are introduced. Finally the challenges and prospects associated with biomass gasification for H2 production are presented.
Novel Carbon-neutral Hydrogen Production Process of Steam Methane Reforming Integrated with Desalination Wastewater-based CO2 Utilization
Nov 2022
Publication
Steam methane reforming (SMR) process is facing serious greenhouse effect problems because of the significant CO2 emissions. To reduce pollution caused by gaseous emissions desalination wastewater can be used because it contains highly concentrated useful mineral ions such as Ca2+ Mg2+ and Na+ which react with carbonate ions. This study proposes a novel SMR process for carbon-neutral hydrogen production integrated with desalination wastewater-based CO2 utilization. A process model for the design of a novel SMR process is proposed; it comprises the following steps: (1) SMR process for hydrogen production; and (2) desalination wastewater recovery for CO2 utilization. In the process model the CO2 from the SMR process was captured using the Na+ ion and the captured ionic CO2 was carbonated using the Ca2+ and Mg2+ ions in desalination wastewater. The levelized cost of hydrogen (LCOH) was assessed to demonstrate the economic feasibility of the proposed process. Therefore 94.5 % of the CO2 from the SMR process was captured and the conversion of MgCO3 and CaCO3 was determined to be 60 % and 99 % respectively. In addition the CO2 emission via the proposed process was determined to be 0.016 kgCO2/kgH2 and the LCOH was calculated to be 2.6 USD/kgH2.
Intelligent Damping Control of Renewable Energy/Hydrogen Energy DC Interconnection System
Oct 2022
Publication
Renewable energy DC hydrogen production has become a new development trend. Due to the interaction between the weak damping of DC network and the negative impedance characteristics of power supply of hydrogen production the actual available power of renewable and hydrogen energy DC interconnection system will be lower than its rated setting value. To solve this problem this paper proposes an intelligent damping control to realize the rated power operation of hydrogen generation power source and significantly improve the hydrogen generation performance. In this paper the nonlinear model under typical control strategies is established in order to adapt to different degrees of disturbance and the damping controller is designed based on state feedback including feedback control law and damping generation formula. On this basis an intelligent method of damping control is proposed to support rapid decision-making. Finally the intelligent damping control method is verified by simulation analysis. It realizes rated power of power supply of hydrogen production by generating only a small amount of damping power and superimposing it on the hydrogen production power
Can Methane Pyrolysis Based Hydrogen Production Lead to the Decarbonisation of Iron and Steel Industry?
Mar 2021
Publication
Decarbonisation of the iron and steel industry would require the use of innovative low-carbon production technologies. Use of 100% hydrogen in a shaft furnace (SF) to reduce iron ore has the potential to reduce emissions from iron and steel production significantly. In this work results from the techno-economic assessment of a H2-SF connected to an electric arc furnace(EAF) for steel production are presented under two scenarios. In the first scenario H2 is produced from molten metal methane pyrolysis in an electrically heated liquid metal bubble column reactor. Grid connected low-temperature alkaline electrolyser was considered for H2 production in the second scenario. In both cases 59.25 kgH2 was required for the production of one ton of liquid steel (tls). The specific energy consumption (SEC) for the methane pyrolysis based system was found to be 5.16 MWh/tls. The system used 1.51 MWh/tls of electricity and required 263 kg/tls of methane corresponding to an energy consumption of 3.65 MWh/tls. The water electrolysis based system consumed 3.96 MWh/tls of electricity at an electrolyser efficiency of 50 KWh/kgH2. Both systems have direct emissions of 129.4 kgCO2/tls. The indirect emissions are dependent on the source of natural gas pellet making process and the grid-emission factor. Indirect emissions for the electrolysis based system could be negligible if the electricity is generated from renewable energy sources. The levellized cost of production(LCOP) was found to be $631 and $669 respectively at a discount rate of 8% for a plant-life of 20 years. The LCOP of a natural gas reforming based direct reduction steelmaking plant of operating under similar conditions was found to be $414. Uncertainty analysis was conducted for the NPV and IRR values.
Review on COx-free Hydrogen from Methane Cracking: Catalysts, Solar Energy Integration and Applications
Oct 2021
Publication
Hydrogen fuel production from methane cracking is a sustainable process compared to the ones currently in practice due to minimal greenhouse gas emissions. Carbon black that is co-produced is a valuable product and can be marketed to other industries. As this is a high-temperature process using concentrated solar energy can further improve its sustainability. In this study a detailed review is conducted to study the advancements in methane cracking for hydrogen production using different catalysts. Various solar reactors developed for methane cracking are discussed. The application of hydrogen to produce other valuable chemicals are outlined. Hydrogen carriers such as methanol dimethyl ether ammonia and urea can efficiently store hydrogen energy and enable easier transportation. Further research in the field of methane cracking is required for reactor scale-up improved economics and to reduce the problems arising from carbon deposition leading to reactor clogging and catalyst deactivation.
Projecting the Future Cost of PEM and Alkaline Water Electrolysers; a CAPEX Model Including Electrolyser Plant Size and Technology Department
Oct 2022
Publication
The investment costs of water electrolysis represent one key challenge for the realisation of renewable hydrogen-based energy systems. This work presents a technology cost assessment and outlook towards 2030 for alkaline electrolysers (AEL) and PEM electrolysers (PEMEL) in the MW to GW range taking into consideration the effects of plant size and expected technology developments. Critical selected data was fitted to a modified power law to describe the cost of an electrolyser plant based on the overall capacity and a learning/technology development rate to derive cost estimations for different PEMEL and AEL plant capacities towards 2030. The analysis predicts that the CAPEX gap between AEL and PEMEL technologies will decrease significantly towards 2030 with plant size until 1 e10 MW range. Beyond this only marginal cost reductions can be expected with CAPEX values approaching 320e400 $/kW for large scale (greater than 100 MW) plants by 2030 with subsequent cost reductions possible. Learning rates for electrolysers were estimated at 25 e30% for both AEL and PEMEL which are significantly higher than the learning rates reported in previous literature.
EU Harmonised Testing Procedure: Determination of Water Electrolyser Energy Performance
Jan 2023
Publication
The objective of this pre-normative research (PNR) document is to present a testing procedure for establishing the energy performance of water (steam) electrolyser systems (WE systems) whether grid-connected or off-grid and individual water electrolysers (WEs)/high-temperature electrolysers (HTEs) for the generation of hydrogen by water/steam electrolysis. The WE systems use electricity mostly from variable renewable energy sources. HTE may additionally utilise (waste) heat from energy conversion and other industrial processes. By applying this procedure the determination of the specific energy consumption per unit of hydrogen output under standard ambient temperature and pressure (SATP) conditions allows for an adequate comparison of different WE systems. Also the energy performance potential of WEs or WE systems employing low-temperature water electrolysis (LTWE) technologies compared to HTE employing high-temperature steam electrolysis (HTSEL) technologies may be established under actual hydrogen output conditions by applying this procedure. The test method is to evaluate the specific energy consumption during steady-state operation at specified conditions including rated input power pressure and temperature of hydrogen recommended by the manufacturer of the WE or WE system. The energy efficiency and the electrical efficiency based on higher and lower heating value of hydrogen can be derived from respectively the specific energy consumption and the specific electric energy consumption as additional energy performance indicators (EPIs). In a plant setting the specific energy consumption of an individual water electrolyser including HTE under hydrogen output conditions may also be determined using this testing procedure. This procedure is intended to be used as a general characterisation method for evaluating the energy performance of WEs including HTEs and systems by the research community and industry alike.
High Proton-Conductive and Temperature-Tolerant PVC-P4VP Membranes towards Medium-Temperature Water Electrolysis
Mar 2022
Publication
Water electrolysis (WE) is a highly promising approach to producing clean hydrogen. Medium-temperature WE (100–350 ◦C) can improve the energy efficiency and utilize the low-grade water vapor. Therefore a high-temperature proton-conductive membrane is desirable to realize the medium-temperature WE. Here we present a polyvinyl chloride (PVC)-poly(4vinylpyridine) (P4VP) hybrid membrane by a simple cross-linking of PVC and P4VP. The pyridine groups of P4VP promote the loading rate of phosphoric acid which delivers the proton conductivity of the PVC-P4VP membrane. The optimized PVC-P4VP membrane with a 1:2 content ratio offers the maximum proton conductivity of 4.3 × 10−2 S cm−1 at 180 ◦C and a reliable conductivity stability in 200 h at 160 ◦C. The PVC-P4VP membrane electrode is covered by an IrO2 anode and a Pt/C cathode delivers not only the high water electrolytic reactivity at 100–180 ◦C but also the stable WE stability at 180 ◦C.
Techno-economic Model and Feasibility Assessment of Green Hydrogen Projects Based on Electrolysis Supplied by Photovoltaic PPAs
Nov 2022
Publication
The use of hydrogen produced from renewable energy enables the reduction of greenhouse gas (GHG) emissions pursued in different international strategies. The use of power purchase agreements (PPAs) to supply renewable electricity to hydrogen production plants is an approach that can improve the feasibility of projects. This paper presents a model applicable to hydrogen projects regarding the technical and economic perspective and applies it to the Spanish case where pioneering projects are taking place via photovoltaic PPAs. The results show that PPAs are an enabling mechanism for sustaining green hydrogen projects.
Techno-economic Assessment of Blue and Green Ammonia as Energy Carriers in a Low-carbon Future
Feb 2022
Publication
Ammonia is an industrial chemical and the basic building block for the fertilizer industry. Lately attention has shifted towards using ammonia as a carbon-free energy vector due to the ease of transportation and storage in liquid state at − 33 ◦C and atmospheric pressure. This study evaluates the prospects of blue and green ammonia as future energy carriers; specifically the gas switching reforming (GSR) concept for H2 and N2 co-production from natural gas with inherent CO2 capture (blue) and H2 generation through an optimized value chain of wind and solar power electrolysers cryogenic N2 supply and various options for energy storage (green). These longer term concepts are benchmarked against conventional technologies integrating CO2 capture: the Kellogg Braun & Root (KBR) Purifier process and the Linde Ammonia Concept (LAC). All modelled plants utilize the same ammonia synthesis loop for a consistent comparison. A cash flow analysis showed that the GSR concept achieved an attractive levelized cost of ammonia (LCOA) of 332.1 €/ton relative to 385.1–385.9 €/ton for the conventional plants at European energy prices (6.5 €/GJ natural gas and 60 €/MWh electricity). Optimal technology integration for green ammonia using technology costs representative of 2050 was considerably more expensive: 484.7–772.1 €/ton when varying the location from Saudi Arabia to Germany. Furthermore the LCOA of the GSR technology drops to 192.7 €/ton when benefitting from low Saudi Arabian energy costs (2 €/GJ natural gas and 40 €/MWh electricity). This cost difference between green and blue ammonia remained robust in sensitivity analyses where input energy cost (natural gas or wind/solar power) was the most influential parameter. Given its low production costs and the techno-economic feasibility of international ammonia trade advanced blue ammonia production from GSR offers an attractive pathway for natural gas exporting regions to contribute to global decarbonization.
Fuelling the Transition Podcast: The Future of Electrolysers and Hydrogen in the UK
Nov 2021
Publication
ITM Power is a leading electrolyser manufacturer and is a globally recognised expert in hydrogen technologies. In this episode Graham Cooley Chief Executive Officer at ITM Power and John Williams Head of Hydrogen Expertise Cluster at AFRY Management Consulting join us to discuss ITM’s recent announcements. This includes raising £250 million to scale up its electrolyser manufacturing capacity to 5GW per annum by 2024 and forming a partnership with Linde to halve electrolyser manufacturing costs within five years. The episode also explores the UK hydrogen strategy how blue hydrogen compares with green hydrogen the role of electrolysers in hydrogen production and providing flexibility to power grids.
The podcast can be found on their website.
The podcast can be found on their website.
Production of Ultra-dense Hydrogen H(0): A Novel Nuclear Fuel
Mar 2021
Publication
Condensation of hydrogen Rydberg atoms (highly electronically excited) into the lowest energy state of condensed hydrogen i.e. the ultra-dense hydrogen phase H(0) has gained increased attention not only from the fundamental aspects but also from the applied point of view. The physical properties of ultra-dense hydrogen H(0) were recently reviewed summarizing the results reported in 50 publications during the last ten years. The main application of H(0) so far is as the fuel and working medium in nuclear particle generators and nuclear fusion reactors which are under commercial development. The first fusion process showing sustained operation above break-even was published in 2015 (AIP Advances) and used ultra-dense deuterium D(0) as fuel. The first generator giving a high-intensity muon flux intended for muon-catalyzed fusion reactors was patented in 2017 using H(0) as the working medium. Here we first focus on the different nuclear processes using hydrogen isotopes for energy generation and then on the detailed processes of formation of H(0). The production of H(0) employs heterogeneous catalysts which are active in hydrogen transfer reactions. Iron oxide-based alkali promoted catalysts function well but also platinum group metals and carbon surfaces are active in this process. The clusters of highly excited Rydberg hydrogen atoms H(l) are formed upon interaction with alkali Rydberg matter. The final conversion step from ordinary hydrogen Rydberg matter H(l) to H(0) is spontaneous and does not require a solid surface. It is concluded that the exact choice of catalyst is not very important. It is also concluded that the crucial feature of the catalyst is to provide excited alkali atoms at a sufficiently high surface density and in this way enabling formation and desorption of H(0) clusters. Finally the relation to industrial catalytic processes which use H(0) formation catalysts is described and some important consequences like the muon and neutron radiation from H(0) are discussed.
Performance and Stability of a Critical Raw Materials-free Anion Exchange Membrane Electrolysis Cell
Feb 2023
Publication
A water electrolysis cell based on anion exchange membrane (AEM) and critical raw materials-free (CRM-free) electrocatalysts was developed. A NiFe-oxide electrocatalyst was used at the anode whereas a series of metallic electrocatalysts were investigated for the cathode such as Ni NiCu NiMo NiMo/KB. These were compared to a benchmark Pt/C cathode. CRMs-free anode and cathode catalysts were synthetized with a crystallite size of about 10 nm. The effect of recirculation through the cell of a diluted KOH solution was investigated. A concentration of 0.5–1 M KOH appeared necessary to achieve suitable performance at high current density. amongst the CRM-free cathodes the NiMo/KB catalyst showed the best performance in the AEM electrolysis cell achieving a current density of 1 A cm− 2 at about 1.7–1.8 V/cell when it was used in combination with a NiFe-oxide anode and a 50 µm thick Fumatech FAA-3–50® hydrocarbon membrane. Durability tests showed an initial decrease of cell voltage with time during 2000 h operation at 1 A cm− 2 until reaching a steady state performance with an energy efficiency close to 80%. An increase of reversible losses during start-up and shutdown cycles was observed. Appropriate stability was observed during cycled operation between 0.2 and 1 A cm− 2 ; however the voltage efficiency was slightly lower than in steady-state operation due to the occurrence of reversible losses during the cycles. Post operation analysis of electrocatalysts allowed getting a better comprehension of the phenomena occurring during the 2000 h durability test.
Energy, Exergy, and Economic Analysis of Cryogenic Distillation and Chemical Scrubbing for Biogas Upgrading and Hydrogen Production
Mar 2022
Publication
Biogas is one of the most important sources of renewable energy and hydrogen production which needs upgrading to be functional. In this study two methods of biogas upgrading from organic parts of municipal waste were investigated. For biogas upgrading this article used a 3E analysis and simulated cryogenic separation and chemical scrubbing. The primary goal was to compare thermoeconomic indices and create hydrogen by reforming biomethane. The exergy analysis revealed that the compressor of the refrigerant and recovery column of MEA contributed the most exergy loss in the cryogenic separation and chemical scrubbing. The total exergy efficiency of cryogenic separation and chemical scrubbing was 85% and 84%. The energy analysis revealed a 2.07% lower energy efficiency for chemical scrubbing. The capital energy and total annual costs of chemical absorption were 56.51 26.33 and 54.44 percent lower than those of cryogenic separation respectively indicating that this technology is more economically feasible. Moreover because the thermodynamic efficiencies of the two methods were comparable the chemical absorption method was adopted for hydrogen production. The biomethane steam reforming was simulated and the results indicated that this method required an energy consumption of 90.48 MJ kgH2 . The hydrogen production intensity equaled 1.98 kmoleH2 kmolebiogas via a 79.92% methane conversion.
How to Power the Energy–Water Nexus: Coupling Desalination and Hydrogen Energy Storage in Mini-Grids with Reversible Solid Oxide Cells
Nov 2020
Publication
Sustainable Development Goals establish the main challenges humankind is called to tackle to assure equal comfort of living worldwide. Among these the access to affordable renewable energy and clean water are overriding especially in the context of developing economies. Reversible Solid Oxide Cells (rSOC) are a pivotal technology for their sector-coupling potential. This paper aims at studying the implementation of such a technology in new concept PV-hybrid energy storage mini-grids with close access to seawater. In such assets rSOCs have a double useful effect: charge/discharge of the bulk energy storage combined with seawater desalination. Based on the outcomes of an experimental proof-of-concept on a single cell operated with salty water the operation of the novel mini-grid is simulated throughout a solar year. Simulation results identify the fittest mini-grid configuration in order to achieve energy and environmental optimization hence scoring a renewable penetration of more than 95% marginal CO2 emissions (13 g/kWh) and almost complete coverage of load demand. Sector-coupling co-production rate (desalinated water versus electricity issued from the rSOC) is 0.29 L/kWh.
Investigation of an Intensified Thermo-Chemical Experimental Set-Up for Hydrogen Production from Biomass: Gasification Process Integrated to a Portable Purification System—Part II
Jun 2022
Publication
Biomass gasification is a versatile thermochemical process that can be used for direct energy applications and the production of advanced liquid and gaseous energy carriers. In the present work the results are presented concerning the H2 production at a high purity grade from biomass feedstocks via steam/oxygen gasification. The data demonstrating such a process chain were collected at an innovative gasification prototype plant coupled to a portable purification system (PPS). The overall integration was designed for gas conditioning and purification to hydrogen. By using almond shells as the biomass feedstock from a product gas with an average and stable composition of 40%-v H2 21%-v CO 35%-v CO2 2.5%-v CH4 the PPS unit provided a hydrogen stream with a final concentration of 99.99%-v and a gas yield of 66.4%.
Main Trends and Research Directions in Hydrogen Generation Using Low Temperature Electrolysis: A Systematic Literature Review
Aug 2022
Publication
Hydrogen (H2 ) is the most abundant element in the universe and it is also a neutral energy carrier meaning the environmental effects of using it are strictly related to the effects of creating the means of producing of that amount of Hydrogen. So far the H2 generation by water electrolysis research field did not manage to break the efficiency barrier in order to consider H2 production as a technology that sustains financially its self-development. However given the complexity of this technology and the overall environmental impacts an up-to-date research and development status review is critical. Thus this study aims to identify the main trends achievements and research directions of the H2 generation using pure and alkaline water electrolysis providing a review of the state of the art in the specific literature. Methods: In order to deliver this a Systematic Literature Review was carried out using PRISMA methodology highlighting the research trends and results in peer review publish articles over more than two years (2020–2022). Findings: This review identifies niches and actual status of the H2 generation by water and alkaline water electrolysis and points out in numbers the boundaries of the 2020–2022 timeline research.
Favorable Start-Up Behavior of Polymer Electrolyte Membrane Water Electrolyzers
Nov 2022
Publication
Dynamically-operated water electrolyzers enable the production of green hydrogen for cross-sector applications while simultaneously stabilizing power grids. In this study the start-up phase of polymer electrolyte membrane (PEM) water electrolyzers is investigated in the context of intermittent renewable energy sources. During the start-up of the electrolysis system the temperature increases which directly influences hydrogen production efficiency. Experiments on a 100 kWel electrolyzer combined with simulations of electrolyzers with up to 1 MWel were used to analyze the start-up phase and assess its implications for operators and system designers. It is shown that part-load start-up at intermediate cell voltages of 1.80 V yields the highest efficiencies of 74.0 %LHV compared to heat-up using resistive electrical heating elements which reaches maximum efficiencies of 60.9 %LHV. The results further indicate that large-scale electrolyzers with electrical heaters may serve as flexible sinks in electrical grids for durations of up to 15 min.
No more items...