Production & Supply Chain

Hydrogen can be produced from a broad range of renewable energy sources acting as a unique energy hub providing low or zero emission energy to all energy consuming sectors. Technically and efficiently producing hydrogen from renewable sources is a key enabler for these developments.<br/>Traditionally hydrogen has been produced from fossil sources by steam methane reforming of natural gas. At present the technology of choice to produce renewable ‘green’ hydrogen is water electrolysis using renewable electricity. The FCH JU has been supporting research and development of electrolyser technology and application projects aiming to increase the energy efficiency of electrolytic hydrogen production from renewable sources and to reduce costs.<br/>This study complements these activities by focusing on renewable hydrogen generation other than electrolysis. In this report these alternative hydrogen generation technologies are described characterized by their technical capabilities maturity and economic performance and assessed for their future potential.<br/>A methodology has been devised to first identify and structure a set of relevant green hydrogen pathways (eleven pathways depicted in the figure below) analyse them at a level of detail allowing a selection of those technologies which fit into and promise early commercialization in the framework of FCH 2 JU’s funding program.<br/>These originally proposed eleven pathways use solar thermal energy sunlight or biomass as major energy input.

Given the limited sources of fossil fuels mankind should find new ways to meet its energy demands. In this regard geothermal and solar energy are acknowledged as reliable safe promising and clean means for this purpose. In this research study a comparative analysis is applied on geothermal and solar-driven multi-generation systems for clean electricity and hydrogen production through energy and exergy assessments. The system consists of an organic Rankine cycle a proton electrolyte membrane electrolyzer and a thermoelectric generator subsystem. The Engineering Equation Solver software has been utilized in order to model the system and obtain the output contours sensitivity analysis and exergy destruction. The results were calculated considering the ambient temperature of Bandar Abbas city as a case study considering the geothermal system due to better performance in comparison to the solar system. According to the sensitivity analysis the turbine efficiency evaporator inlet temperature thermoelectric generator suitability criterion pump efficiency and evaporator inlet mass flow rate are the most influential parameters. Also the exergy analysis showed that the utmost system's exergy destruction is pertinent to the evaporator and the least is related to the pump. In addition the system produces 352816 kWh and 174.913 kg of electrical power and hydrogen during one year.

In this work the design of the hardware architecture to implement an algorithm for optimizing the Hydrogen Productivity Rate (HPR) in a Microbial Electrolysis Cell (MEC) is presented. The HPR in the MEC is maximized by the golden section search algorithm in conjunction with a super-twisting controller. The development of the digital architecture in the implementation step of the optimization algorithm was developed in the Very High Description Language (VHDL) and synthesized in a Field Programmable Gate Array (FPGA). Numerical simulations demonstrated the feasibility of the proposed optimization strategy embedded in an FPGA Cyclone II. Results showed that only.

The growing consumption of global energy has posed serious challenges to environmental protection and energy supplies. A promising solution is via introducing clean and sustainable energy sources including photoelectrochemical hydrogen fuel production. 2D materials such as transition metal trichalcogenphosphites (MPCh₃) are gaining more and more interest for their potential as photocatalysts. Crystals of transition metal selenophosphites namely MnPSe₃ FePSe₃ and ZnPSe₃ were tested as photocatalysts for the hydrogen evolution reaction (HER). ZnPSe3 is the one that exhibited the lowest overpotential and the higher response to the light during photocurrent experiments in acidic media. For this reason among the crystals in this work it is the most promising for the photocatalyzed production of hydrogen.

Solutions that simulate hydrometallurgical base metal process streams with high nickel (Ni) and minor platinum (Pt) concentrations were used to create Pt/Ni nanoparticles on TiO₂ nanotube surfaces. For this electrochemical deposition – redox replacement (EDRR) was used that also allowed to control the nanoparticle size density and Pt/Ni content of the deposited nanoparticles. The Pt/Ni nanoparticle decorated titanium dioxide nanotubes (TiO₂ nanotubes) become strongly activated for photocatalytic hydrogen (H₂) evolution. Moreover EDRR facilitates nanoparticle formation without the need for any additional chemicals and is more effective than electrodeposition alone. Actually a 10000-time enrichment level of Pt took place on the TiO₂ surface when compared to Pt content in the solution with the EDRR method. The results show that hydrometallurgical streams offer great potential as an alternative raw material source for industrial catalyst production when coupled with redox replacement electrochemistry.

Climate policy objectives require zero emissions across all sectors including steelmaking. The fundamental process changes needed for reaching this target are yet relatively unexplored. In this paper we propose and assess a potential design for a fossil-free steelmaking process based on direct reduction of iron ore with hydrogen. We show that hydrogen direct reduction steelmaking needs 3.48 MWh of electricity per tonne of liquid steel mainly for the electrolyser hydrogen production. If renewable electricity is used the process will have essentially zero emissions. Total production costs are in the range of 361–640 EUR per tonne of steel and are highly sensitive to the electricity price and the amount of scrap used. Hydrogen direct reduction becomes cost competitive with an integrated steel plant at a carbon price of 34–68 EUR per tonne CO2 and electricity costs of 40 EUR/MWh. A key feature of the process is flexibility in production and electricity demand which allows for grid balancing through storage of hydrogen and hot-briquetted iron or variations in the share of scrap used.

Hydrogen produced from renewable electricity will play an important role in deep decarbonisation of industry. However adding large electrolyser capacities to a low-carbon electricity system also increases the need for additional electricity generation from variable renewable energies. This will require hydrogen production to be variable unless other sources provide sufficient flexibility. Existing sources of flexibility in hydro-thermal systems are hydropower and thermal generation which are both associated with sustainability concerns. In this work we use a dispatch model for the case of Sweden to assess the power system operation with large-scale electrolysers assuming that additional wind power generation matches the electricity demand of hydrogen production on average. We evaluate different scenarios for restricting the flexibility of hydropower and thermal generation and include 29 different weather years to test the impact of variable weather regimes. We show that (a) in all scenarios electrolyser utilisation is above 60% on average (b) the inter-annual variability of hydrogen production is substantial if thermal power is not dispatched for electrolysis and (c) this problem is aggravated if hydropower flexibility is also restricted. Therefore either long-term storage of hydrogen or backup hydrogen sources may be necessary to guarantee continuous hydrogen flows. Large-scale dispatch of electrolysis capacity supported by wind power makes the system more stable if electrolysers ramp down in rare hours of extreme events with low renewable generation. The need for additional backup capacities in a fully renewable electricity system will thus be reduced if wind power and electrolyser operation are combined in the system.

Developing non-precious catalysts as Pt substitutes for electrochemical hydrogen evolution reaction (HER) with superior stability in acidic electrolyte is of critical importance for large-scale low-cost hydrogen production from water. Herein we report a CoCrFeNiAl high-entropy alloy (HEA) electrocatalyst with self-supported structure synthesized by mechanical alloying and spark plasma sintering (SPS) consolidation. The HEA after HF treatment and in situ electrochemical activation for 4000 cycles of cyclic voltammetry (HF-HEAa2) presents favourable activity with overpotential of 73 mV to reach a current density of 10 mA cm⁻² and a Tafel slope of 39.7 mV dec⁻¹. The alloy effect of Al/Cr with Co/Fe/Ni at atomic level high-temperature crystallization as well as consolidation by SPS endow CoCrFeNiAl HEA with high stability in 0.5 M H₂SO₄ solution. The superior performance of HF-HEAa2 is related with the presence of metal hydroxides/oxides groups on HEA.

Hydrogen is a zero-carbon footprint energy source with high energy density that could be the basis of future energy systems. Membrane-based water electrolysis is one means by which to produce high-purity and sustainable hydrogen. It is important that the scientific community focus on developing electrolytic hydrogen systems which match available energy sources. In this review various types of water splitting technologies and membrane selection for electrolyzers are discussed. We highlight the basic principles recent studies and achievements in membrane-based electrolysis for hydrogen production. Previously the NafionTM membrane was the gold standard for PEM electrolyzers but today cheaper and more effective membranes are favored. In this paper CuCl–HCl electrolysis and its operating parameters are summarized. Additionally a summary is presented of hydrogen production by water splitting including a discussion of the advantages disadvantages and efficiencies of the relevant technologies. Nonetheless the development of cost-effective and efficient hydrogen production technologies requires a significant amount of study especially in terms of optimizing the operation parameters affecting the hydrogen output. Therefore herein we address the challenges prospects and future trends in this field of research and make critical suggestions regarding the implementation of comprehensive membrane-based electrolytic systems.

Variable renewable energy (VRE) is expected to play a major role in the decarbonization of the electricity sector. However decarbonization via VRE requires a fleet of flexible dispatchable plants with low CO2 emissions to supply clean power during times with limited wind and sunlight. These plants will need to operate at reduced capacity factors with frequent ramps in electricity output posing techno-economic challenges. This study therefore presents an economic assessment of a new near-zero emission power plant designed for this purpose. The gas switching reforming combined cycle (GSR-CC) plant can produce electricity during times of low VRE output and hydrogen during times of high VRE output. This product flexibility allows the plant to operate continuously even when high VRE output makes electricity production uneconomical. Although the CO2 avoidance cost of the GSR-CC plant (€61/ton) was similar to the benchmark post-combustion CO2 capture plant under baseload operation GSR-CC clearly outperformed the benchmark in a more realistic scenario where continued VRE expansion forces power plants into mid-load operation (45% capacity factor). In this scenario GSR-CC promises a 5 %-point higher annualized investment return than the post-combustion benchmark. GSR-CC therefore appears to be a promising concept for a future scenario with high VRE market share and CO2 prices provided that a large market for clean hydrogen is established.