Production & Supply Chain

Rapid industrialization is consuming too much energy and non-renewable energy resources are currently supplying the world’s majority of energy requirements. As a result the global energy mix is being pushed towards renewable and sustainable energy sources by the world’s future energy plan and climate change. Thus hydrogen has been suggested as a potential energy source for sustainable development. Currently the production of hydrogen from fossil fuels is dominant in the world and its utilization is increasing daily. As discussed in the paper a large amount of hydrogen is used in rocket engines oil refining ammonia production and many other processes. This paper also analyzes the environmental impacts of hydrogen utilization in various applications such as iron and steel production rocket engines ammonia production and hydrogenation. It is predicted that all of our fossil fuels will run out soon if we continue to consume them at our current pace of consumption. Hydrogen is only ecologically friendly when it is produced from renewable energy. Therefore a transition towards hydrogen production from renewable energy resources such as solar geothermal and wind is necessary. However many things need to be achieved before we can transition from a fossil-fuel-driven economy to one based on renewable energy

Environmental issues related to greenhouse gas emissions are progressively pushing the transition toward fossil-free energy scenario in which renewable energies such as solar and wind power will unavoidably play a key role. However for this transition to succeed significant issues related to renewable energy storage have to be addressed. Power-to-X (PtX) technologies have gained increased attention since they actually convert renewable electricity to chemicals and fuels that can be more easily stored and transported. H2 production through water electrolysis is a promising approach since it leads to the production of a sustainable fuel that can be used directly in hydrogen fuel cells or to reduce carbon dioxide (CO2) in chemicals and fuels compatible with the existing infrastructure for production and transportation. CO2 electrochemical reduction is also an interesting approach allowing the direct conversion of CO2 into value-added products using renewable electricity. In this review attention will be given to technologies for sustainable H2 production focusing on water electrolysis using renewable energy as well as on its remaining challenges for large scale production and integration with other technologies. Furthermore recent advances on PtX technologies for the production of key chemicals (formic acid formaldehyde methanol and methane) and fuels (gasoline diesel and jet fuel) will also be discussed with focus on two main pathways: CO2 hydrogenation and CO2 electrochemical reduction.

With renewable energy sources projected to become the dominant source of electricity hydrogen has emerged as a crucial energy carrier to mitigate their intermittency issues. Water electrolysis is the most developed alternative to generate green hydrogen so far. However in the past two decades steam electrolysis has attracted increasing interest and aims to become a key player in the portfolio of electrolytic hydrogen. In practice steam electrolysis follows two distinct operational approaches: Solid Oxide Electrolysis Cell (SOEC) and Proton Exchange Membrane (PEM) at high temperature. For both technologies this work analyses critical cell components outlining material characteristics and degradation issues. The influence of operational conditions on the performance and cell durability of both technologies is thoroughly reviewed. The analytical comparison of the two electrolysis alternatives underscores their distinct advantages and drawbacks highlighting their niche of applications: SOECs thrive in high temperature industries like steel production and nuclear power plants whereas PEM steam electrolysis suits lower temperature applications such as textile and paper. Being PEM steam electrolysis less explored this work ends up by suggesting research lines in the domain of i) cell components (membranes catalysts and gas diffusion layers) to optimize and scale the technology ii) integration strategies with renewable energies and iii) use of seawater as feedstock for green hydrogen production.

As countries work towards achieving net-zero emissions the need for cleaner fuels has become increasingly urgent. Hydrogen produced from fossil fuels with carbon capture and storage (blue hydrogen) has the potential to play a significant role in the transition to a low-carbon economy. This study examined the technical and economic potential of blue hydrogen produced at 600 MWth(LHV) and scaled up to 1000 MWth(LHV) by benchmarking sorption-enhanced steam reforming process against steam methane reforming (SMR) autothermal gasheated reforming (ATR-GHR) integrated with carbon capture and storage (CCS) and SMR with CCS. Aspen Plus® was used to develop the process model which was validated using literature data. Cost sensitivity analyses were also performed on two key indicators: levelised cost of hydrogen and CO2 avoidance cost by varying natural gas price electricity price CO2 transport and storage cost and carbon price. Results indicate that at a carbon price of 83 £/tCO2e the LCOH for SE-SR of methane is the lowest at 2.85 £/kgH2 which is 12.58% and 22.55% lower than that of ATR-GHR with CCS and SMR plant with CCS respectively. The LCOH of ATR-GHR with CCS and SMR plant with CCS was estimated to be 3.26 and 3.68 £/kgH2 respectively. The CO2 avoidance cost was also observed to be lowest for SE-SR followed by ATR-GHR with CCS then SMR plant with CCS and was observed to reduce as the plant scaled to 1000 MWth(LHV) for these technologies.

This article challenges the view that zero carbon hydrogen from steam methane reforming (SMR) is prohibitively expensive and that the cost of CO2 capture increases exponentially as residual emissions approach zero; a flawed narrative often eliminating SMR produced hydrogen as a route to net zero. We show that the capture and geological storage of 100% of the fossil CO2 produced in a SMR is achievable with commercially available post-combustion capture technology and an open art solvent. The Levelised Cost of Hydrogen (LCOH) of 69£/MWhth HHV (2.7£/kg) for UK production remains competitive to other forms of low carbon hydrogen but retains a hydrogen lifecycle carbon intensity of 5 gCO2e/MJ (LHV) due to natural gas supply chain and embodied greenhouse gas (GHG) emissions. Compensating for the remaining lifecycle GHG emissions via Direct Air Capture with geological CO2 Storage (DACCS) increases the LCOH to 71–86 £/MWhth HHV (+3–25%) for a cost estimate of 100–1000 £/tCO2 for DACCS and the 2022 UK natural gas supply chain methane emission rates. Finally we put in perspective the cost of CO2 avoidance of fuel switching from natural gas to hydrogen with long term price estimates for natural gas use and DACCS and hydrogen produced from electrolysis.

Economical offshore wind developments depend on alternatives for cost-efficient transmission of the generated energy to connecting markets. Distance to shore availability of an offshore power grid and scale of the wind farm may impede export through power cables. Conversion to H2 through offshore electrolysis may for certain offshore wind assets be a future option to enable energy export. Here we analyse the cost sensitivity of offshore electrolysis for harvesting offshore wind in the North Sea using a technology-detailed multi-carrier energy system modelling framework for analysis of energy export. We include multiple investment options for electric power and hydrogen export including HVDC cables new hydrogen pipelines tie-in to existing pipelines and pipelines with linepacking. Existing hydropower is included in the modelling and the effect on offshore electrolysis from increased pumping capacity in the hydropower system is analysed. Considering the lack of empirical cost data on offshore electrolysis as well as the high uncertainty in future electricity and H2 prices we analyse the cost sensitivity of offshore electrolysis in the North Sea by comparing costs relative to onshore electrolysis and energy prices relative to a nominal scenario. Offshore electrolysis is shown to be particularly sensitive to the electricity price and an electricity price of 1.5 times the baseline assumption was needed to provide sufficient offshore energy for any significant offshore electrolysis investments. On the other hand too high electricity prices would have a negative impact on offshore electrolysis because the energy is more valuable as electricity even at the cost of increased wind power curtailment. This shows that there is a window-of-opportunity in terms of onshore electricity where offshore electrolysis can play a significant role in the production of H2 . Pumped hydropower increases the maximum installed offshore electrolysis at the optimal electricity and H2 prices and makes offshore electrolysis more competitive at low electricity prices. Linepacking can make offshore electrolysis investments more robust against low H2 and high electricity prices as it allow for more variable H2 production through storing excess energy from offshore. The increased electrolysis capacity needed for variable electrolyser operation and linepacking is installed onshore due to its lower CAPEX compared to offshore installations.

This study proposes a multitype electrolytic collaborative hydrogen production model for optimizing the capacity configuration of renewable energy off grid hydrogen production systems. The electrolytic hydrogen production process utilizes the synergistic electrolysis of an alkaline electrolyzer (AEL) and proton exchange membrane electrolyzer (PEMEL) fully leveraging the advantages of the low cost of the AEL and strong regulation characteristics of the PEMEL. For the convenience of the optimization solution the article constructs a mixed linear optimization model that considers the constraints during system operation with the objective function of minimizing total costs while meeting industrial production requirements. Gurobi is used for the optimal solution to obtain the optimal configuration of a renewable energy off grid hydrogen production system. By comparing and analyzing the optimal configuration under conventional load and high-load conditions it is concluded that collaborative electrolysis has advantages in improving resource consumption and reducing hydrogen production costs. This is of great significance for optimizing the capacity configuration of off grid hydrogen production systems and improving the overall economic benefits of the system.

Methane reforming is an interesting resource for obtaining hydrogen. DBD plasma-catalysis allows a direct use of electricity for methane reforming reactions such as direct methane reforming (MR) dry methane reforming (DMR) and steam methane reforming (SMR). In this work the first comprehensive comparison of these three routes for hydrogen production is experimentally and systematically investigated using dielectric barrier discharge (DBD) plasma and various catalyst formulations. Among the three routes SMR is the most effective achieving significantly higher methane conversion rates (24 %) and hydrogen content (80 %). DMR produces predominantly syngas mixture whereas MR yields hydrogen along with other light carbon compounds. In SMR route the favorable textural properties of Ni/Al2O3 are responsible for its high methane conversion rates while Ni/CeO2 increases hydrogen content since it favors the water-gas shift reaction especially at high power inputs. Therefore SMR using a suitable catalyst stands out as the most feasible reforming route for hydrogen production.

Hydrogen is gaining prominence in global efforts to combat greenhouse gas emissions and climate change. While steam methane reforming remains the predominant method of hydrogen production alternative approaches such as water electrolysis and methane cracking are gaining attention. The bridging technology – methane cracking – has piqued scientific interest with its lower energy requirement (74.8 kJ/mol compared to steam methane reforming 206.278 kJ/mol) and valuable by-product of filamentous carbon. Nevertheless challenges including coke formation and catalyst deactivation persist. This review focuses on two main reactor types for catalytic methane decomposition – fixed-bed and fluidised bed. Fixed-bed reactors excel in experimental studies due to their operational simplicity and catalyst characterisation capabilities. In contrast fluidised-bed reactors are more suited for industrial applications where efforts are focused on optimising the temperature gas flow rate and particle characterisation. Furthermore investigations into various fluidised bed regimes aim to identify the most suitable for potential industrial deployment providing insights into the sustainable future of hydrogen production. While the bubbling regime shows promise for upscaling fluidised bed reactors experimental studies on turbulent fluidised-bed reactors especially in achieving high hydrogen yield from methane cracking are limited highlighting the technology’s current status not yet reaching commercialisation.

This review comprehensively evaluates the integration of solar-powered electrolytic hydrogen (H2) production and captured carbon dioxide (CO2) management for clean fuel production considering all potential steps from H2 production methods to CO2 capture and separation processes. It is expected that the near future will cover CO2-capturing technologies integrated with solar-based H2 production at a commercially viable level and over 5 billion tons of CO2 are expected to be utilized potentially for clean fuel production worldwide in 2050 to achieve carbon-neutral levels. The H2 production out of hydrocarbon-based processes using fossil fuels emits greenhouse gas emissions of 17-38 kg CO2/kg H2. On the other hand . renewable energy based green hydrogen production emits less than 2 kg CO2/kg H2 which makes it really clean and appealing for implementation. In addition capturing CO2 and using for synthesizing alternative fuels with green hydrogen will help generate clean fuels for smart cities. In this regard the most sustainable and promising CO2 capturing method is post-combustion with an adsorption-separation-desorption processes using monoethanolamine adsorbent with high CO2 removal efficiencies from flue gases. Consequently this review article provides perspectives on the potential of integrating CO2-capturing technologies and renewable energy-based H2 production systems for clean production to create sustainable cities and communities.