Production & Supply Chain

Hydrogen production from renewable energy sources is a crucial pathway to achieving the carbon peak target and realizing the vision of carbon neutrality. The hydrogen production from offshore superconducting wind power (HPOSWP) integrated systems as an innovative technology in the renewable energy hydrogen production field holds significant market potential and promising development prospects. This integrated technology based on research into high-temperature superconducting generator (HTSG) characteristics and electrolytic water hydrogen production (EWHP) technology converts offshore wind energy (OWE) into hydrogen energy locally through electrolysis with hydrogen storage being shipped and controlled liquid hydrogen (LH2) circulation ensuring a stable low-temperature environment for the HTSGs’ refrigeration system. However due to the significant instability and intermittency of offshore wind power (OWP) this HPOSWP system can greatly affect the dynamic adaptability of the EWHP system resulting in impure hydrogen production and compromising the safety of the LH2 cooling system and reduce the fitness of the integrated system for wind electricity–hydrogen heat multi-field coupling. This paper provides a comprehensive overview of the fundamental structure and characteristics of this integrated technology and further identifies the key challenges in its application including the dynamic adaptability of electrolytic water hydrogen production technology as well as the need for large-capacity long-duration storage solutions. Additionally this paper explores the future technological direction of this integrated system highlighting the need to overcome the limitations of electrical energy adaptation within the system improve product purity and achieve large-scale applications.

Water electrolysis is a promising technology for sustainable energy conversion and storage of intermittent and fluctuating renewable energy sources and production of high-purity hydrogen for fuel cells and various industrial applications. Low-temperature electrochemical water splitting technologies include alkaline proton exchange membrane and anion exchange membrane water electrolyses which normally consist of two coupled half reactions: the hydrogen evolution reaction (HER) and the oxygen evolution reaction (OER). Despite the advances over decades formidable challenges still exist and hinder the practical application of large-scale energy-efficient and economically viable water electrolysis including large energy penalty sluggish kinetics high cost of precious metal based electrocatalysts possible H2/O2 gas crossover difficulty in storage and distribution of H2. Herein we first briefly introduce the fundamentals of water electrolysis summarize the recommended standardized electrochemical characterization protocols and demonstrate the metrics and key performance indicators that are used to evaluate the performances of HER and OER electrocatalysts and electrolyser cells. Then we present six new strategies to mitigate the technical challenges in conventional water electrolysis. These emerging strategies for disruptive innovation of water electrolysis technology include overall water electrolysis based on bifunctional nonprecious electrocatalysts (or pre-catalysts) magnetic field-assisted water electrolysis decoupled water electrolysis hybrid water electrolysis acid/alkaline asymmetric electrolyte electrolysis and tandem water electrolysis. Finally the remaining challenges perspectives and future directions are discussed. This review will provide guidance and inspire more endeavours to deepen the mechanistic understanding and advance the development of water electrolysis.

Direct seawater electrolysis (DSE) has emerged as a compelling route to sustainable hydrogen production leveraging the vast global reserves of seawater. However the inherently complex composition of seawater—laden with halide ions multivalent cations (Mg2+ Ca2+) and organic/biological impurities—presents formidable challenges in maintaining both selectivity and durability. Chief among these obstacles is mitigating chloride corrosion and suppressing chlorine evolution reaction (ClER) at the anode while also preventing the precipitation of magnesium and calcium hydroxides at the cathode. This review consolidates recent advances in material engineering and cell design strategies aimed at controlling undesired side reactions enhancing electrode stability and maximizing energy efficiency in DSE. We first outline the fundamental thermodynamic and kinetic hurdles introduced by Cl⁻ and other impurities. This discussion highlights how these factors accelerate catalyst degradation and drive suboptimal reaction pathways. We then delve into innovative approaches to improve selectivity and durability of DSE—such as engineering protective barrier layers tuning electrolyte interfaces developing corrosion-resistant materials and techniques to minimize Mg/Ca-related precipitations. Finally we explore emerging reactor configurations including asymmetric and membrane-free electrolyzers which address some barriers for DSE commercialization. Collectively these insights provide a framework for designing next-generation DSE systems which can achieve large-scale cost-effective and environmentally benign hydrogen production.

The utilization of renewable energy for hydrogen production presents a promising pathway towards achieving carbon neutrality in energy consumption. Water electrolysis utilizing pure water has proven to be a robust technology for clean hydrogen production. Recently seawater electrolysis has emerged as an attractive alternative due to the limitations of deep-sea regions imposed by the transmission capacity of long-distance undersea cables. However seawater electrolysis faces several challenges including the slow kinetics of the oxygen evolution reaction (OER) the competing chlorine evolution reaction (CER) processes electrode degradation caused by chloride ions and the formation of precipitates on the cathode. The electrode and catalyst materials are corroded by the Cl− under long-term operations. Numerous efforts have been made to address these issues arising from impurities in the seawater. This review focuses on recent progress in developing high-performance electrodes and electrolyser designs for efficient seawater electrolysis. Its aim is to provide a systematic and insightful introduction and discussion on seawater electrolysers and electrodes with the hope of promoting the utilization of offshore renewable energy sources through seawater electrolysis.

The exploration of green energy is a demanding issue due to climate change and ecology. Green energy hydrogen is gaining importance in the area of alternative energy sources. Many methods are being explored for this but most of them are utilizing other sources of energy to produce hydrogen. Therefore these approaches are not economic and acceptable at the industrial level. Sunlight and nuclear radiation as free or low-cost energy sources to split water for hydrogen. These methods are gaining importance in recent times. Therefore attempts are made to explore the latest updates in direct radiation water-splitting methods of hydrogen production. This article discusses the advances made in green hydrogen production by water splitting using visible and UV radiations as these are freely available in the solar spectrum. Besides water splitting by gamma radiation (a low-cost energy source) is also reviewed. Eforts are also made to describe the water-splitting mechanism in photo- and gamma-mediated water splitting. In addition to these challenges and future perspectives have also been discussed to make this article useful for further advanced research.

In recent years the intensification of human activities has led to an increase in waste production and energy demand. The treatment of pollutants contained in wastewater coupled to energy recovery is an attractive solution to simultaneously reduce environmental pollution and provide alternative energy sources. Hydrogen represents a clean energy carrier for the transition to a decarbonized society. Hydrogen can be generated by photosynthetic water splitting where oxygen and hydrogen are produced and the process is driven by the light energy absorbed by the photocatalyst. Alternatively hydrogen may be generated from hydrogenated pollutants in water through photocatalysis and the overall reaction is thermodynamically more favourable than water splitting for hydrogen. This review is focused on recent developments in research surrounding photocatalytic and photoelectrochemical hydrogen production from pollutants that may be found in wastewater. The fundamentals of photocatalysis and photoelectrochemical cells are discussed along with materials and efficiency determination. Then the review focuses on hydrogen production linked to the oxidation of compounds found in wastewater. Some research has investigated hydrogen production from wastewater mixtures such as olive mill wastewater juice production wastewater and waste activated sludge. This is an exciting area for research in photocatalysis and semiconductor photoelectrochemistry with real potential for scale up in niche applications.

Low-cost alkaline water electrolysis from renewable energy sources (RESs) is suitable for large-scale hydrogen production. However fluctuating RESs lead to poor performance of alkaline water electrolyzers (AWEs) at low loads. Here we explore two urgent performance issues: inefficiency and inconsistency. Through detailed operation process analysis of AWEs and the established equivalent electrical model we reveal the mechanisms of inefficiency and inconsistency of low-load AWEs are related to the physical structure and electrical characteristics. Furthermore we propose a multi-mode self-optimization electrolysis converting strategy to improve the efficiency and consistency of AWEs. In particular compared to a conventional dc power supply we demonstrate using a lab-scale and large-scale commercially available AWE that the maximum efficiency can be doubled while the operation range of the electrolyzer can be extended from 30–100% to 10–100% of rated load. Our method can be easily generalized and can facilitate hydrogen production from RESs.

Sorption-enhanced steam reforming (SorESR) is an advanced thermochemical process integrating in-situ CO2 capture via solid sorbents to significantly enhance hydrogen production and purity. By coupling CO2 adsorption with steam reforming SorESR shifts the reaction equilibrium toward increased H₂ yield surpassing the limitations of conventional steam reforming (SR). The efficacy of SorESR critically depends on the physicochemical properties of the solid CO2 sorbents employed. This review critically evaluates widely studied sorbents including Ca-based Mg-based hydrotalcite-like and alkali ceramic sorbents focusing on their CO2 capture capacity reaction kinetics thermal stability and cyclic durability under SR conditions. Furthermore recent progress in multifunctional sorbent-catalysts that synergistically facilitate catalytic steam reforming alongside CO2 sorption is critically discussed. Moreover the review summarises recent performance achievements and proposes strategies to improve sorbent capacity and reaction kinetics thereby making the SorESR process more appealing for commercial applications. Large-scale SorESR implementation is expected to substantially increase hydrogen production efficiency while concurrently reducing CO2 emissions and advancing sustainable energy technologies. This review offers novel insights into the development of advanced sorbent-catalyst systems and provides new strategies for enhancing SorESR efficiency and scalability for commercial H2 Production.

In the context of mounting concerns over carbon emissions and the need to accelerate the energy transition green hydrogen has emerged as a strategic solution for decarbonizing hard-to-abate sectors. This paper introduces a methodological innovation by proposing the Green Hydrogen Efficiency Index (GHEI) a unified and quantitative framework that integrates multiple stages of the hydrogen value chain into a single comparative metric. The index encompasses six core criteria: electricity source water treatment electrolysis efficiency compression end-use conversion and associated greenhouse gas emissions. Each are normalized and weighted to reflect different performance priorities. Two weighting profiles are adopted: a first profile which assigns equal importance to all criteria referred to as the balanced profile and a second profile derived using the analytic hierarchy process (AHP) based on structured expert judgment named the AHP profile. The methodology was developed through a systematic literature review and was applied to four representative case studies sourced from the academic literature covering diverse configurations and geographies. The results demonstrate the GHEI’s capacity to distinguish the energy performance of different green hydrogen routes and support strategic decisions related to technology selection site planning and logistics optimization. The results highlight the potential of the index to contribute to more sustainable hydrogen value chains and advance decarbonization goals by identifying pathways that minimize energy losses and maximize system efficiency

The increasing interest in off-grid green hydrogen production has elevated the importance of reliable techno-economic assessment (TEA) tools to support investment and planning decisions. However limited operational data and inconsistent modeling approaches across existing tools introduce significant uncertainty in cost estimations. This study presents a comprehensive review and comparative analysis of seven TEA tools—ranging from simplified calculators to advanced hourly based simulation platforms—used to estimate the Levelized Cost of Hydrogen (LCOH) in off-grid Hydrogen Production Plants (HPPs). A standardized simulation framework was developed to input consistent technical economic and financial parameters across all tools allowing for a horizontal comparison. Results revealed a substantial spread in LCOH values from EUR 5.86/kg to EUR 8.71/kg representing a 49% variation. This discrepancy is attributed to differences in modeling depth treatment of critical parameters (e.g. electrolyzer efficiency capacity factor storage and inflation) and the tools’ temporal resolution. Tools that included higher input granularity hourly data and broader system components tended to produce more conservative (higher) LCOH values highlighting the cost impact of increased modeling realism. Additionally the total project cost—more than hydrogen output—was identified as the key driver of LCOH variability across tools. This study provides the first multi-tool horizontal testing protocol a methodological benchmark for evaluating TEA tools and underscores the need for harmonized input structures and transparent modeling assumptions. These findings support the development of more consistent and reliable economic evaluations for off-grid green hydrogen projects especially as the sector moves toward commercial scale-up and policy integration.

This study evaluated the economic feasibility of producing hydrogen from natural gas via thermal degradation in a plasma reactor. Plasma pyrolysis where natural gas passes through the space between electrodes and serves as the working medium enables high hydrogen yields without emitting carbon monoxide or carbon dioxide. Instead the primary products are hydrogen and solid carbon. Unlike conventional methods this approach requires no catalysts addressing a major technological limitation. A thermodynamic equilibrium model based on Gibbs free energy minimization was used to analyze the process over a temperature range of 500–2500 K. The results indicate an optimal temperature of approximately 1500 K which achieved a 99.5% methane conversion by mass. Considering the capital and operating costs and profit margins the hydrogen production cost was estimated at 3.49 EUR/kg. The sensitivity analysis revealed that the price of solid carbon had the most significant impact which potentially raised the hydrogen cost to 4.53 EUR/kg or reduced it to 1.70 EUR/kg.

The use of hydrogen as an energy carrier represents a promising alternative for mitigating climate change. However its practical application requires achieving a high degree of purity throughout the production process. In this study the influence of the type of catalytic support on H2 production via steam glycerol reforming was evaluated with the objective of obtaining syngas with the highest possible H2 concentration. Three types of support were analyzed: two natural materials (zeolite and dolomite) and one metal oxide alumina. Alumina and dolomite were coated with Ni at different loadings while zeolite was only evaluated without Ni. Reforming experiments were carried out at a constant temperature of 850 ◦C with continuous monitoring of H2 CO2 CO and CH4 concentrations. The results showed that zeolite yielded the lowest H2 concentration (51%) mainly due to amorphization at high temperatures and the limited effectiveness of physical adsorption processes. In contrast alumina and dolomite achieved H2 purities of around 70% which increased with Ni loading. The improvement was particularly significant in dolomite owing to its higher porosity and the recarbonation processes of CaO enabling H2 purities of up to 90%.

Natural hydrogen or "white hydrogen" has recently garnered attention as a viable and cost-effective energy resource due to its low-carbon footprint and high energy density positioning it as a key contributor to the transition towards a sustainable low-carbon energy system. This study represents Alberta’s first systematic effort to evaluate natural hydrogen potential in the province using publicly available geological geospatial and gas composition datasets. By mapping hydrogen occurrences against key geological features in the Western Canadian Sedimentary Basin (WCSB) we identify regions with strong geological potential for natural hydrogen generation migration and accumulation while addressing data uncertainties. Within the WCSB formations like the Montney Cardium Bearpaw Manville Belly River McMurray and Lea Park are identified as zones likely for hydrogen generation by prominent mechanisms including hydrocarbon decomposition water-rock reactions with iron-rich sediments and organic pyrolysis. Formation proximity to the underlying Canadian Shield may also suggest potential for basement-derived hydrogen migration via deep-seated faults and shear zones. Salt deposits (Elk Point Group - Prairie evaporites Cold Lake and Lotsberg) and deep shales (e.g. Kaskapau Lea Park Wapiabi) provide effective cap rock potential while reservoirs like porous sandstone (e.g. Dunvegan Spirit River Cardium) and fractured carbonate (e.g. Keg River) formations offer favorable accumulation conditions. Hydrogen occurrences in relation to geological features identify Southern Eastern and West-Central plains as prominent natural Hydrogen generation and accumulation areas. Alberta’s established energy infrastructure as well as subsurface expertise positions it as a potential leader in natural hydrogen exploration. As Alberta’s first systematic investigation this study provides a preliminary assessment of natural hydrogen potential and outlines recommended next steps to guide future exploration and research. Targeted research on specific generation and accumulation mechanisms and source identification through isotopic and geochemical fingerprinting will be crucial for exploration de-risking and viability assessment in support of net-zero emission initiatives.

This study explores the generation of natural hydrogen through the serpentinization of onshore ultramafic rocks highlighting its potential as a clean energy resource. By investigating critical factors such as mineral composition temperature and pressure the research develops an empirical model using multiple regression analysis to predict hydrogen generation rates under varying geological conditions. A novel five-stage volumetric calculation methodology is introduced to estimate hydrogen production from ultramafic rock bodies. The application of this framework to the Giles Complex an ultramafic-mafic intrusion in Australia suggests a hydrogen generation potential of approximately 2.24 × 1013 kg of hydrogen through partial serpentinization. This estimate is based on the assumed mineral composition depth and temperature conditions within the intrusion which influence the extent of serpentinization reactions. The findings demonstrate the significant potential of ultramafic complexes for natural hydrogen production and provide a foundation for advancing natural hydrogen exploration refining predictive models and supporting sustainable energy development.

This study evaluates the feasibility of employing rainwater as an alternative feedstock for hydrogen production via electrolysis. While conventional systems typically rely on high-purity water—such as deionized or distilled variants—these can be cost-prohibitive and environmentally intensive. Rainwater being naturally available and minimally treated presents a potential sustainable alternative. In this work a series of comparative experiments was conducted using a proton exchange membrane electrolyzer system operating with both deionized water and rainwater collected from different Austrian locations. The chemical composition of rainwater samples was assessed through inductively coupled plasma ion chromatography and visual rapid tests to identify impurities and ionic profiles. The electrolyzer’s performance was evaluated under equivalent operating conditions. Results indicate that rainwater in some cases yielded comparable or marginally superior efficiency compared to deionized water attributed to its inherent ionic content. The study also examines the operational risks linked to trace contaminants and explores possible strategies for their mitigation.

With the intensification of the global energy crisis hydrogen has attracted significant attention as a high-energy-density and zero-emission clean energy source. Traditional hydrogen production methods are dependent on fossil fuels and simultaneously contribute to environmental pollution. The aqueous phase reforming (APR) of renewable biomass and its derivatives has emerged as a research hotspot in recent years due to its ability to produce green hydrogen in an environmentally friendly manner. This review provides an overview of the advancements in APR of lignocellulosic biomass as a sustainable and environmentally friendly method for hydrogen production. It focuses on the reaction pathways of various biomass feedstocks (such as glucose cellulose and lignin) as well as the types and performance of catalysts used in the APR process. Finally the current challenges and future prospects in this field are briefly discussed.

The global emphasis on clean energy has increased interest in producing hydrogen from petroleum reservoirs through in situ combustion-based processes. While field practices have demonstrated the feasibility of co-producing hydrogen and oil the question of which offers greater economic potential oil or hydrogen remains central to ongoing discussions especially as researchers explore ways to produce hydrogen exclusively from petroleum reservoirs. This study presents the first integrated techno-economic model comparing oil and hydrogen production under varying injection strategies using CMG STARS for reservoir simulations and GoldSim for economic modeling. Key technical factors including injection compositions well configurations reservoir heterogeneity and formation damage (issues not addressed in previous studies) were analyzed for their impact on hydrogen yield and profitability. The results indicate that CO2-enriched injection strategies enhance hydrogen production but are economically constrained by the high costs of CO2 procurement and recycling. In contrast air injection although less efficient in hydrogen yield provides a more cost-effective alternative. Despite the technological promise of hydrogen oil revenue remains the dominant economic driver with hydrogen co-production facing significant economic challenges unless supported by policy incentives or advancements in gas lifting separation and storage technologies. This study highlights the economic trade-offs and strategic considerations crucial for integrating hydrogen production into conventional petroleum extraction offering valuable insights for optimizing hydrogen co-production in the context of a sustainable energy transition. Additionally while the present work focuses on oil reservoirs future research should extend the approach to natural gas and gas condensate reservoirs which may offer more favorable conditions for hydrogen generation.

The pyrolysis and oxidative steam reforming (P-OSR) of different types of plastics (HDPE PP PET and PS) has been carried out in a two reactor system provided with a conical spouted bed reactor (CSBR) and a fluidized bed reactor (FBR). The effect plastic composition has on the oxidative steam reforming step has been analyzed using two space time values (3.1 gcatalyst min gplastic − 1 and 12.5 gcatalyst min gplastic − 1 ) at a reforming temperature of 700 ◦C S/P ratio of 3 and ER of 0.2 (optimum conditions for autothermal reforming). The different composition of the plastics leads to differences in the yields and compositions of pyrolysis products and consequently in the performance of the oxidative steam reforming step. High conversions (> 97 %) have been achieved by using a space time of 12.5 gcat min gplastic − 1 with H2 production increasing as follows: PET ≪ PS < HDPE ≤ PP. A maximum H2 production of 25.5 wt% has been obtained by using PP which is lower than that obtained in the process of pyrolysis and in line conventional steam reforming (P-SR) of the same feedstock (34.8 wt%). The lowest H2 production (10.5 wt%) has been achieved when PET was used due to the high oxygen content of this plastic. The results obtained in this study prove that P-OSR performs very well with different feedstock thereby confirming the versatility and efficiency of this process to produce a hydrogen-rich gas.

The integration of renewable energy into industrial processes is crucial for reducing the carbon footprint of conventional hydrogen production. This work presents detailed design optical–thermal simulation and performance analysis of a solar parabolic dish (SPD) system for supplying high-temperature steam to a Steam Methane Reforming (SMR) plant. A 5 m diameter dish with a focal length of 3 m was designed and optimized using COMSOL Multiphysics (version 6.2) and MATLAB (version R2023a). Optical ray tracing confirmed a geometric concentration ratio of 896× effectively focusing solar irradiation onto a helical cavity receiver. Thermal–fluid simulations demonstrated the system’s capability to superheat steam to 551 ◦C at a mass flow rate of 0.0051 kg/s effectively meeting the stringent thermal requirements for SMR. The optimized SPD system with a 5 m dish diameter and 3 m focal length was designed to supply 10% of the total process heat (≈180 GJ/day). This contribution reduces natural gas consumption and leads to annual fuel savings of approximately 141000 SAR (Saudi Riyal) along with a substantial reduction in CO2 emissions. These quantitative results confirm the SPD as both a technically reliable and economically attractive solution for sustainable blue hydrogen production.

Given the economic industrial and environmental value of green dihydrogen (H2) optimization of water electrolysis as a means of producing H2 is essential. Binders are a crucial component of electrocatalysts yet they remain largely underdeveloped with a significant lack of standardization in the field. Therefore targeted research into the development of alternative binder systems is essential for advancing performance and consistency. Binders essentially act as the key to regulating the electrode (support)–catalyst–electrolyte interfacial junctions and contribute to the overall reactivity of the electrocatalyst assembly. Therefore alternative binders were explored with a focus on cost efficiency and environmental compatibility striving to achieve desirable activity and stability. Herein the alkaline hydrogen evolution reaction (HER) was investigated and the sluggish water dissociation step was targeted. Controlled hydrophilic poly(vinyl alcohol)-based hydrogel binders were designed for this application. Three hydrogel binders were evaluated without incorporated electrocatalysts namely PVA145 PVA145-blend-bPEI1.8 and PVA145-blend-PPy. Interestingly the study revealed that the hydrophilicity of the binders exhibited an enhancing effect on the observed activity resulting in improved performance compared to the commercial binder Nafion™. Notably the PVA145 system stands out with an overpotential of 224 mV at−10 mA·cm−2 (geometric) in 1.0 M KOH compared to the 238 mV exhibited by Nafion™. Inclusion of Pt as active material in PVA145 as binder exhibited a synergistic increase in performance achieving a mass activity of 1.174 A.cm−2.mg−1 Pt in comparison to Nafion™’s 0.344 A.cm−2.mg−1 Pt measured at−150 mV vs RHE. Our research aimed to contribute to the development of cost-effective and efficient binder systems stressing the necessity to challenge the dominance of the commercially available binders.

The present work focused on the comparison between HHO and hydrogen electrolyzers in design gas production and various parameters which affect the performance and efficiency of alkaline electrolyzers. The primary goal is to generate the highest possible hydrogen and HHO gas flow rates. Hydrogen and HHO were produced using 3 mm electrode of stainless steel 316L with 224 cm2 surface area. Hydroxy and hydrogen rates were affected by electrolyte content cell connection electric current operating time electrolyte temperature and voltage. Maximum HHO generation values were 1020 1076 1125 and 1175 mL min−1 n at 5 10 15 and 20 g L−1 of sodium hydroxide (NaOH) with supply currents of 15 15.3 15.6 and 16 A respectively. Once it stabilized after 30 min the temperature increased to 26 30 35 and 38 °C respectively and remained there. With currents of 18 18.45 18.7 19.2 19.5 and 19.8 A hydrogen output peak values after 60 min. stayed constant at 680 734 785 846 897 and 945 mL min-1. at 5 10 15 and 20 g L−1 NaOH catalyst concentrations. At 5 10 15 and 20 g L−1 catalyst ratios the temperatures were elevated to constant values of 28.5 32 37.9 40.5 41.4 and 43 °C respectively. With cell design [4C3A19N] electrolyte concentration of 5 g L−1 NaOH and current of 14 A maximum HHO productivity was 866 mL min−1. and 74.23% efficiency. In a cell design of [4C5A17N] with catalyst content of 10 g L−1 maximum productivity was 680 mL min−1 for hydrogen and highest production efficiency of 72.85% was attained at 18 A.

Solid oxide electrolysis (SOEL) is considered an efficient option for largely emission-free hydrogen production and thus for supporting the decarbonization of the process industry. The thermodynamic advantages of high-temperature operation can be utilized particularly when heat integration from subsequent processes is realized. As the produced hydrogen is usually required at a higher pressure level the operating pressure of the electrolysis is a relevant design parameter. The study compares pressurized and near-atmospheric designs of 126 MW SOEL systems with and without the integration of process heat from a downstream ammonia synthesis and the inefficiencies that occur in the processes. Furthermore process improvements by sweep-air utilization are investigated. Pinch analysis is applied to determine the potential of internal heat recovery and the minimum external heating and cooling demand. It is shown that pressurized SOEL operation does not necessarily decrease the overall power consumption for compression due to the high power requirement of the sweep-air compressor. The exergetic efficiencies of the standalone SOEL processes achieve similar values of = 81 %. Results further show that integrating the heat of reaction from ammonia synthesis can replace almost the entire electrically supplied thermal energy thereby improving the overall exergetic efficiency by up to 3.5 percentage points. However the exergetic efficiency strongly depends on the applied air ratio. The highest exergetic efficiency of 86 % can be achieved by employing sweep-air utilization with an expander. The results demonstrate that integrating downstream process heat and applying sweep-air utilization can significantly enhance overall efficiency and thus reduce external energy requirements.

Solar-driven water electrolysis has emerged as a prominent technology for the production of green hydrogen facilitated by advancements in both water electrolyzers and solar cells. Nevertheless the majority of integrated solar-to-hydrogen systems still struggle to exceed 20% efficiency particularly in large-scale applications. This limitation arises from suboptimal coupling methodologies and system-level inefficiencies that have rarely been analyzed. To address these challenges this study investigates the fundamental principles of solar hydrogen production and examines key energy losses in photovoltaic-electrolyzer systems. Subsequently it systematically discusses optimization strategies across three dimensions: (1) enhancing photovoltaic (PV) system output under variable irradiance (2) tailoring electrocatalysts and electrolyzer architectures for high-performance operation and (3) minimizing coupling losses through voltage-matching technologies and energy storage devices. Finally we review existing large-scale solar hydrogen infrastructure and propose strategies to overcome barriers related to cost durability and scalability. By integrating material innovation with system engineering this work offers insights to advance solar-powered electrolysis toward industrial applications.

Sustainable process design has become increasingly important in transitioning from conventional to sustainable chemical production yet comprehensive sustainability assessment at the preliminary design stage remains a challenge. This study addresses this gap by proposing a hierarchical framework that integrates the Principles Criteria and Indicators (PC&I) method with multi-criteria decision-making (MCDM) tools including entropy weighting TOPSIS and weighted addition. The framework guides the systematic selection of sustainability indicators across economic environmental and social dimensions. To validate its applicability a case study on hydrogen production via four process routes natural gas reforming biomass-derived syngas methanol purge gas recovery and alkaline electrolysis is conducted. Results show that the methanol purge gas process exhibits the best overall sustainability followed by biomass syngas and alkaline electrolysis. The case demonstrates the framework’s capability to differentiate between alternatives under conflicting sustainability dimensions. This work provides a structured and replicable approach to support sustainable decision-making in early-stage chemical process design.

As global awareness of environmental protection increases hydrogen is seen as a promising solution due to its high energy density and zero-emission combustion. The PEM electrolyze combined with renewable energy power generation is an effective method to solve the problem of hydrogen production. The market competitiveness of PEM electrolyte will be enhanced in the future and the equipment cost can be reduced by 35.8%. The fast dynamic response performance of PEM electrolyzes especially during start-up and shutdown affects system flexibility and stability. The 190 Nm3/h test platform is established to study the fast dynamic response performance considering the cold startup thermal start-up and shutdown behaviors. The results shown that the 190 Nm³/h PEM electrolyze required 6340 s to achieve cold start-up 1100 s to achieve thermal start-up and 855 s to complete shutdown. When operating stably the temperature fluctuation of the PEM remains below 5 °C demonstrating the excellent temperature control performance. However during cold start-up and shutdown the concentrations of hydrogen and oxygen fluctuate significantly which can easily lead to a decrease in system performance. These findings provide guidance for optimizing the design and operating parameters of PEM Electrolyze systems.