Production & Supply Chain

Ammonia (NH3) decomposition offers a pathway for water purification and green hydrogen production yet conventional catalysts often suffer from poor stability due to agglomeration. This study presents a novel (FeCoNiCuMn)O high-entropy ceramic (HEC) catalyst synthesized via fast-moving bed pyrolysis (FMBP) which prevents aggregation and enhances catalytic performance. The HEC catalyst applied as an anode in electrochemical oxidation (EO) demonstrated a uniform spinel (AB2O4) structure confirmed by XRD XRF and ICP-OES. Electronic structure characterization using UPS and LEIPS revealed a bandgap of 4.722 eV with EVBM and ECBM values facilitating redox reactions. Under 9 V and 50 mA/cm² current density the HEC electrode achieved 99% ammonia decomposition within 90 min and retained over 90% efficiency after four cycles. Surface analysis by XPS and HAXPES indicated oxidation state variations confirming catalyst activity and stability. Gas chromatography identified H2 N2 and O2 as the main products with ~64.7% Faradaic efficiency for H2 classifying it as green hydrogen. This dual-function approach highlights the (FeCoNiCuMn)O HEC anode as a promising and sustainable solution for wastewater treatment and hydrogen production.

A two-stage system is used for hydrogen (H2) and methane (CH4) production from sucrose wastewater. The H2- producing reactor is operated at pH temperature (T) and hydraulic retention time (HRT) of 5.5 35 ◦C 24 h respectively. While operating conditions of 7–8 pH 35 ◦C T and 144 h HRT are used to conduct the CH4 production stage. The effects of two different parameters as sucrose concentration (5 10 and 20 g/L) and addition of ferrous ions (60 and 120 mg/L) are investigated. Both H2 and CH4 productions are increased at high sucrose concentrations. However the optimum H2 and CH4 yields of 163.2 mL-H2/g-sucrose and 211.8 mL-CH4/g-TVS are obtained at 5 g-sucrose/L. At 5 g-sucrose/L addition of Fe2+ increases the H2 yield to 192.5 and 176.2 mLH2/g-sucrose corresponding to 60 and 120 mg-Fe2+/L respectively. Higher removal efficiencies and total energy recovery are measured using the two-stage system than the single-stage reactor.

While hydrogen production through pure water splitting remains a key focus in solar hydrogen research photocatalytic seawater splitting presents a more sustainable alternative better aligned with global development goals amid increasing freshwater scarcity. Nevertheless the deactivation of the photocatalyst by the corrosion of various ions present in seawater as well as the chloride ions’ redox side reaction limits the practical use of the photocatalytic seawater splitting process. In this context sulfur has emerged as a crucial component in photocatalytic composites for seawater splitting owing to its unique chemical properties. It acts as a chlorine-repulsive agent effectively suppressing chloride ion oxidation which mitigates corrosion enhances structural stability and significantly improves overall photocatalytic performance in saline environments. This review offers a thorough explanation of the basic ideas of solar-driven seawater splitting delves into various synthesis strategies and explores recent advancements in sulfur-based composites for efficient hydrogen generation using seawater. Optimizing synthesis techniques and incorporating strategies like doping cocatalyst and heterojunctions significantly enhance the performance of sulfur-based photocatalysts for seawater splitting. Future advances include integrating AI-guided material discovery sustainable use of industrial sulfur waste and precise control of sacrificial agents to ensure long-term efficiency and stability.

In recent years the utilization of aluminium (Al) Al alloys and their composite powder and anode encourages the generation of green hydrogen through hydrolysis and water splitting electrolysis with zero emissions. As such in this study the development and characterization of Al Al alloys and Al-based composite powder and compacted Al composites for clean hydrogen production using hydrolysis and water splitting processes were reviewed. Herein based on the available literature it is worth mentioning that the incorporation of active additives such as h-BN Bi@C g-C3N4 MoS2 Ni In Fe and BiOCl@CNTs in the Al-based composites using ball milling melting smelting casting and spark plasma sintering technique remarkably improved the rate of hydrogen evolution and hydrogen gas conversion yield particularly during hydrolysis of Al-water reaction. Again Al-based electrodes with improved electrical conductivity notably results in better water splitting electrolysis as well as fast chemical reaction in achieving hydrogen gas production at low energy consumption with efficiency. Though notwithstanding the significance of Al Al alloy and Al-based composite hydrogen generation performances there are still some challenges associated with the Al-based materials for hydrogen production via hydrolysis and water electrolysis. For example the low current density and poor electrochemical properties of Al which on the other hand results in long induction time high overpotential and cost remains a gap to bridge. Hence the authors concluded the review study with recommendations for future improvement of Al-based composite electrodes on hydrogen production and sustainability via hydrolysis and water electrolysis. Thus the study will pave the way for further research on clean hydrogen energy generation.

This research evaluates four hydrogen (H2) production technologies via water electrolysis (WE): alkaline water electrolysis (AWE) proton exchange membrane electrolysis (PEME) anion exchange membrane electrolysis (AEME) and solid oxide electrolysis (SOE). Two scoring and ranking methods the MACBETH method and the Pugh decision matrix are utilized for this evaluation. The scoring process employs nine decision criteria: capital expenditure (CAPEX) operating expenditure (OPEX) operating efficiency (SOE) startup time (SuT) environmental impact (EI) technology readiness level (TRL) maintenance requirements (MRs) supply chain challenges (SCCs) and levelized cost of H2 (LCOH). The MACBETH method involves pairwise technology comparisons for each decision criterion using seven qualitative judgment categories which are converted into quantitative scores via M-MACBETH software (Version 3.2.0). The Pugh decision matrix benchmarks WE technologies using a baseline technology—SMR with CCS—and a three-point scoring scale (0 for the baseline +1 for better −1 for worse). Results from both methods indicate AWE as the leading H2 production technology which is followed by AEME PEME and SOE. AWE excels due to its lowest CAPEX and OPEX highest TRL and optimal operational efficiency (at ≈7 bars of pressure) which minimizes LCOH. AEME demonstrates balanced performance across the criteria. While PEME shows advantages in some areas it requires improvements in others. SOE has the most areas needing enhancement. These insights can direct future R&D efforts toward the most promising H2 production technologies to achieve the net-zero goal.

Green hydrogen produced through renewable-powered electrolysis has the potential to revolutionize energy systems; however its widespread adoption hinges on achieving competitive production costs. A critical challenge lies in optimising the hydrogen production process to address solar and wind energy’s high variability and intermittency. This paper explores the role of artificial intelligence (AI) in reducing and streamlining hydrogen production costs by enabling advanced process optimisation focusing on electricity cost management and system-wide efficiency improvements.

The solid oxide electrolysis cell (SOEC) presents significant potential for transforming renewable energy into green hydrogen. Traditional modeling approaches however are constrained by their applicability to specific SOEC systems. This study aims to develop robust data-driven models that accurately capture the complex relationships between input and output parameters within the hydrogen production process. To achieve this advanced machine learning techniques were utilized including Random Forests (RFs) Convolutional Neural Networks (CNNs) Linear Regression Artificial Neural Networks (ANNs) Elastic Net Ridge and Lasso Regressions Decision Trees (DTs) Support Vector Machines (SVMs) k-Nearest Neighbors (KNN) Gradient Boosting Machines (GBMs) Extreme Gradient Boosting (XGBoost) Light Gradient Boosting Machines (LightGBM) CatBoost and Gaussian Process. These models were trained and validated using a dataset consisting of 351 data points with performance evaluated through various metrics and visual methods. The dataset’s suitability for model training was confirmed using the Monte Carlo outlier detection method. Results indicate that within the dataset and evaluation framework of this study ANNs CNNs Gradient Boosting and XGBoost models have demonstrated high accuracy and reliability achieving the largest R-squared scores and the smallest error metrics. Sensitivity analysis reveals that all input parameters significantly influence hydrogen production magnitude. Game-theoretic SHAP values underline current and cathode electrode conditions as critical factors. This research determines the performance of machine learning models particularly ANNs CNNs Gradient Boosting and XGBoost in predicting hydrogen production through the SOEC process. The outcomes of this paper can provide a certain reference for related research and applications in the hydrogen production field.

Polymer Electrolyte Membrane Water Electrolyzers (PEMWEs) attract significant attention for producing green hydrogen. However their widespread application remains hindered by high production costs. This study develops cost-effective and high-performance 3D-printed gyroid structures as porous transport layers (PTLs) for the anode of PEMWEs. Experimental results demonstrate that the PTL’s structure critically influences its performance which depends on its design. Among the four gyroid structures evaluated the G10 electrode exhibited the best performance in electrochemical tests conducted under various ex-situ conditions simulating real-world operation. Furthermore the 3D-printed G10 electrode undergoes Pt coating and is compared with commercially available PTLs. The commercial PTL (C3) shows a current density of 138.488 mA cm−2 whereas the G10-1.00 μm Pt electrode achieves a significantly higher current density of 584.692 mA cm−2 at 1.9V. The gyroid structure is a promising avenue for developing high-energy and low-cost PEMWEs and other related technologies.

More than 0.13 million tons of waste are generated annually making conventional methods of treatment including anaerobic digestion incineration and landfilling insufficient.Thus a long-term solution is required.Therefore this study used a process modeling through Aspen Plus V11 to investigate how variations in waste types and gasification temperatures affect the ability to producing hydrogen. Additionally the use of a Steam Rankin Cycle has been used to optimize the economy through generation. To explore the potential of various type of waste proximate and Ultimate analysis have been done experimentally in lab and some of them (Rice Husk Rice Straw Sugar-cane Baggage Cow-dung etc.) have been taken from references. This study presents validation against experimental data using dolomite and olivine as bed materials. The model showed strong agreement with experimental results accurately predicting hydrogen concentration CO and CO2. A detailed thermodynamic analysis revealed an increase in hydrogen purity from 50.9 % in raw syngas to 100 % after pressure swing adsorption (PSA) accompanied by an exergy reduction from 48.99 MW to 34.68 MW due to separation and thermal losses. Parametric studies demonstrated that gasification temperatures between 750 °C and 800 °C and steam-to-biomass ratios of 0.4–0.5 optimize hydrogen production. Feedstock type significantly influenced performance; rice straw rice husk jute stick and cow dung exhibited higher hydrogen yields compared to food waste. The model predicted a hydrogen production rate of approximately 1020  kg/h per ton of dry feedstock with an overall system efficiency of 48.5 % based on exergy analysis.

This paper provides a comprehensive analytical review and life cycle assessment (LCA) of solid oxide electrolysis cells (SOECs) for hydrogen production. As the global energy landscape shifts toward cleaner and more sustainable solutions SOECs offer a promising pathway for hydrogen generation by utilizing water as a feedstock. Despite their potential challenges in efficiency economic viability and technological barriers remain. This review explores the evolution of SOECs highlighting key advancements and innovations over time and examines their operational principles efficiency factors and classification by operational temperature range. It further addresses critical technological challenges and potential breakthroughs alongside an indepth assessment of economic feasibility covering production cost comparisons hydrogen storage capacity and plant viability and an LCA evaluating environmental impacts and sustainability. The findings underscore SOECs’ progress and their crucial role in advancing hydrogen production while pointing to the need for further research to overcome existing limitations and enhance commercial viability.

Solar energy is now one of the most affordable and widely available energy sources. However densely populated cities like Hong Kong often lack the land needed for large-scale solar deployment. Floating solar photovoltaics (FPV) offer a promising alternative by using water surfaces such as reservoirs while providing additional benefits over ground-mounted systems including competition with urban development such as housing and infrastructure. The advantage of this system has been explored in parts of the world while Hong Kong is yet to fully exploit it despite the presence of pilot projects. This study uses PVsyst to evaluate FPV deployment across Hong Kong’s reservoirs estimating over 7 TWh of potential annual electricity generation. Even with 60 % surface coverage generation reaches 4.6 TWh/year with LCOE between $0.036–$0.038/kWh. In parallel green hydrogen is explored as a clean energy storage solution and alternative transport fuel. By using electricity from FPV systems hydrogen production via electrolysis is assessed through HOMER Pro. Results show annual hydrogen output ranging from 180502 kg to 36310221 kg depending on reservoir size with associated LCOH between $10.2/kg and $19.4/kg. The hydrogen produced could support ongoing hydrogen bus projects and future expansion to other vehicle types as Hong Kong moves toward a hydrogen-based transport system. After coupling the FPV systems with hydrogen-generation units the new LCOEs are found to be between $0.029–4.01/ kWh. Thus suggesting the feasibility of a hydrogen-integrated FPV system in Hong Kong.

This work explores the integration of Proton Exchange Membrane (PEM) electrolysis waste heat with district heating networks (DHN) aiming to enhance the overall energy efficiency and economic viability of hydrogen production systems. PEM electrolysers generate substantial amounts of low-temperature waste heat during operation which is often dissipated and left unutilised. By recovering such thermal energy and selling it to district heating systems a synergistic energy pathway that supports both green hydrogen production and sustainable urban heating can be achieved. The study investigates how the electrolyser’s operating temperature ranging between 50 and 80 ◦C influences both hydrogen production and thermal energy availability exploring trade-offs between electrical efficiency and heat recovery potential. Furthermore the study evaluates the compatibility of the recovered heat with common heat emission systems such as radiators fan coils and radiant floors. Results indicate that valorising waste heat can enhance the overall system performance by reducing the electrolyser’s specific energy consumption and its levelized cost of hydrogen (LCOH) while supplying carbon-free thermal energy for the end users. This integrated approach contributes to the broader goal of sector coupling offering a pathway toward more resilient flexible and resource-efficient energy systems.

Harnessing renewable energy for sustainable hydrogen production is a pivotal step towards a greener future. This study explores integrating solar tower (ST) technology with thermal energy storage and a power cycle to drive a PEM electrolyzer for green hydrogen production. A comprehensive investigation is conducted to evaluate the thermodynamic performance of the integrated system including an exergoeconomic analysis to evaluate and optimize techno-economic performance. Exergy analysis reveals that the main components responsible for 84 % of the total exergy destruction are the ST with 60 % the heat exchanger with 16 % and the electrolyzer with 8 %. The hydrogen production cost varies with operational parameters e.g. increased solar radiation reduces the cost to 4.5 $/kg at 1000 W/m2 . Furthermore the overall system performance is evaluated and monitored using overall effectiveness exergy efficiency and hydrogen production cost for full-day operation at hourly intervals based on the design set operating conditions versus optimized ones using the conjugate optimization. The findings indicate that the optimization improved the average overall effectiveness from 29.3 % to 31.2 % and the average exergy efficiency from 36 % to 40 % while the average hydrogen cost is reduced from 4.6 to 4.3 $/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.

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.

This study develops and optimizes a solar-powered system for hydrogen generation with oxygen and power coproducts addressing the need for efficient scalable carbon-free energy solutions. The system combines a linear parabolic collector a Steam Rankine cycle and a Proton Exchange Membrane Electrolyzer (PEME) to produce electricity for electrolysis. Thermodynamic modeling was accomplished in Engineering Equation Solver while a hybrid Artificial Intelligence (AI) framework combining Artificial Neural Networks and Genetic Algorithms in Statistica coupled with Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) decision support optimized technical and economic performance. Optimization considered seven key decision variables covering collector design thermodynamic inputs and component efficiencies. The optimization achieved energy and exergy efficiencies of 30.83 % and 26.32 % costing 47.02 USD/h and avoiding CO2 emissions equivalent to 190 USD/ton. Economic and exergy analyses showed the solar and hydrogen units had the highest costs (38.17 USD/h and 9.61 USD/h) with 4503 kWh of exergy destruction to generate 575 kWh of electricity. A case study across six cities suggested that Perth Bunbury and Adelaide with higher solar irradiance delivered the highest annual power and hydrogen outputs consistent with irradiance–electrolyzer correlation. Unlike conventional single-site studies this work delivers a climate-responsive multi-city analysis integrating solar thermal and PEME within an AI-driven framework. By linking techno-economic performance with quantified environmental value and co-production synergies of hydrogen oxygen and electricity the study highlights a novel pathway for scalable clean hydrogen measurable CO2 reductions and global decarbonization with future work focused on digital twins and dynamic uncertainty-aware optimization.

Blue hydrogen is a key pathway for reducing greenhouse gas emissions while utilizing natural gas with carbon capture and storage (CCS). This study conducts a techno-economic and environmental analysis of a greenfield blue hydrogen plant in Saskatchewan Canada integrating both SMR and ATR technologies. Unlike previous studies that focus mainly on production units this research includes all process and utility systems such as H2 and CO2 compression air separation refrigeration co-generation and gas dehydration. Aspen HYSYS simulations revealed ATR’s energy demand is 10% lower than that of SMR. The hydrogen production cost was USD 3.28/kg for ATR and USD 3.33/kg for SMR while a separate study estimated a USD 2.2/kg cost for design without utilities highlighting the impact of indirect costs. Environmental analysis showed ATR’s lower Global Warming Potential (GWP) compared to SMR reducing its carbon footprint. The results signified the role of utility integration site conditions and process selection in optimizing energy efficiency costs and sustainability.