Production & Supply Chain

The escalating global energy demand has intensified research into sustainable hydrogen production particularly through water splitting. A highly promising avenue involves photocatalytic water splitting which leverages readily available earth-abundant materials to generate clean hydrogen from water using only renewable energy sources. Among the various catalytic materials investigated metal-organic frameworks (MOFs) have recently attracted considerable interest. Their tunable porosity high crystallinity as well as the customisable molecular structures position them as a transformative class of catalysts for efficient and sustainable photocatalytic hydrogen generation. This review examines MOFs detailing their structural characteristics unique properties and diverse synthetic routes. The discussion extends to the various composite materials that can be derived from MOFs with particular emphasis on their application in photocatalytic hydrogen production via water splitting. Furthermore the review identifies current challenges hindering MOF implementation and proposes modification strategies to overcome these limitations. The concluding section summarises the presented information and future perspectives on the continued development of MOF composites for enhanced photocatalytic hydrogen production from water.

This extensive study delves into analyzing carbon dioxide (CO2)-capturing green hydrogen plant exploring its operation using multiple electrolysis techniques and examining their efficiency and impact on environment. The solar energy is used for the electrolysis to make hydrogen. Emitted CO2 from thermal power plants integrate with green hydrogen and produces methanol. It is a process crucial for mitigating environmental damage and fostering sustainable energy practices. The findings demonstrated that solid oxide electrolysis is the most effective process by which hydrogen can be produced with significant rate of 90 % efficiency. Moreover proton exchange membrane (PEM) becomes a viable and common method with an 80 % efficiency whereas the alkaline electrolysis has a moderate level of 63 % efficiency. Additionally it was noted that the importance of seasonal fluctuations where the capturing of CO2 is maximum in summer months and less in the winter is an important factor to consider in order to maximize the working of the plant and the allocation of resources.

Green hydrogen is emerging as a pivotal energy carrier in the global transition toward decarbonization offering a sustainable alternative to fossil fuels in sectors such as heavy industry transportation power generation and long-duration energy storage. Despite its potential large-scale deployment remains hindered by significant economic technological and infrastructure challenges. Current production costs for green hydrogen range from USD 3.8 to 11.9/kg H2 significantly higher than gray hydrogen at USD 1.5–6.4/kg H2 due to high electricity prices and electrolyzer capital costs exceeding USD 2000 per kW. This review critically examines the key bottlenecks in green hydrogen production focusing on water electrolysis technologies electrocatalyst limitations and integration with renewable energy sources. The economic viability of green hydrogen is constrained by high electricity consumption capital-intensive electrolyzer costs and operational inefficiencies making it uncompetitive with fossil fuel-based hydrogen. Infrastructure and supply chain challenges including limited hydrogen storage transport complexities and critical material dependencies further restrict market scalability. Additionally policy and regulatory gaps disparities in financial incentives and the absence of a standardized certification framework hinder international trade and investment in green hydrogen projects. This review also highlights market trends and global initiatives assessing the role of government incentives and cross-border collaborations in accelerating hydrogen adoption. While technological advancements and cost reductions are progressing overcoming these challenges requires sustained innovation stronger policy interventions and coordinated efforts to develop a resilient scalable and cost-competitive green hydrogen sector.

Hybrid water electrolysis system was designed by using Ruthenium-Tin Oxide (RuSn12.4O2) electrocatalyst as anode material for efficient hydrogen production enhancing energy conversion efficiency. The RuSn12.4O2 Electrocatalyst was synthesized by hydrothermal method and exhibited exceptional activity making it an optimal choice for Iodide oxidation reaction (IOR) and enabling energy-saving hydrogen production. The two-electrode acidic electrolyzer reduced voltage consumption by 0.51 V at 10 mA cm-2 compared to oxygen evolution reaction (OER) at the same current density. This hybrid electrolysis system achieved a remarkable reduction in energy consumption of over 40 % compared to OER process. The Chrono-potentiometric test demonstrated that the RuSn12.4O2 electro-catalyst’s superior stability and low overpotential increase of 70 mV at 10 mAcm-2 . The RuSn12.4O2 electro-catalyst Tafel slope is also a crucial metric for understanding kinetic characteristics in both IOR and OER processes. Thus RuSn12.4O2 electro-catalyst in IOR has a lower Tafel slope (61 mV dec-1) than that in OER according to the Tafel slopes determined from linear sweep voltammetry (LSV) curves. Additionally at various potentials the electro-catalyst's activity toward IOR to produce hydrogen demonstrated exceptional performance in this electrolysis system without causing any catalyst degradation.

Achieving climate neutrality goals is inseparable from the sustainable development of modern cities. Municipal wastewater treatment plants (WWTP) are among the starting points when moving cities to Net-zero Greenhouse Gas (GHG) emissions and climate neutrality. This study focuses on the analysis of the integration of green hydrogen (H2) and biomethane technologies in WWTPs and on the impact of this integration on WWTPs’ energy neutrality. This study treats WWTP as an integrated energy system with certain inputs and outputs. Currently such systems in most cases have a significantly negative energy balance and in addition fossil fuel energy sources are used. Key findings highlight that the integration of green hydrogen production in WWTPs and the efficient utilization of electrolysis by-products can make such energy systems neutral or even positive. This study provides an analysis of the main technical presumptions for the successful integration of green hydrogen and biomethane production processes in WWTP. Furthermore a case study of a real wastewater treatment plant is presented.

Offshore green hydrogen production lacks of flexible and scalable supervisory control approaches for multistack electrolyzers raising the need for extendable and high-performance solutions. This work presents a two-stage nonlinear model predictive control (MPC) method. First an MPC stage generates a discrete on-off electrolyzer switching decision through algebraic relaxation of a Boolean signal. The second MPC stage receives the stack’s on-off operation decision and optimizes hydrogen production. This is a novel approach for solving a mixed-integer nonlinear program (MINP) in multi-stack electrolyzer control applications. In order to realize the MPC the advantages of the implicit multilinear time-invariant (iMTI) model class are exploited for the first time for proton exchange membrane (PEM) electrolyzer models. A modular flexible and scalable framework in MATLAB is built. The tensor based iMTI model in canonical polyadic (CP) decomposed form breaks the curse of dimensionality and enables effective model composition for electrolyzers. Simulation results show an appropriate multilinear model representation of the nonlinear system dynamics in the operation region. A sensitivity analysis identified three numeric factors as decisive for the effectiveness of the MPC approach. The classic rule-based control methods Daisy Chain and Equal serve as reference. Over two weeks and under a wind power input profile the MPC strategy performs better regarding the objective of hydrogen production compared to the Daisy Chain (4.60 %) and Equal (0.43 %) power distribution controllers. As a side effect of the optimization a convergence of the degradation states is observed.

Since the early days of space exploration the efficient production of oxygen and hydrogen via water electrolysis has been a central task for regenerative life-support systems. Water electrolysers are however challenged by the near-absence of buoyancy in microgravity resulting in hindered gas bubble detachment from electrodes and diminished electrolysis efficiencies. Here we show that a commercial neodymium magnet enhances water electrolysis with current density improvements of up to 240% in microgravity by exploiting the magnetic polarization of the electrolyte and the magnetohydrodynamic force. We demonstrate that these interactions enhance gas bubble detachment and displacement through magnetic convection and achieve passive gas–liquid phase separation. Two model magnetoelectrolytic cells a proton-exchange membrane electrolyser and a magnetohydrodynamic drive were designed to leverage these forces and produce oxygen and hydrogen at near-terrestrial efficiencies in microgravity. Overall this work highlights achievable lightweight low-maintenance and energy-efficient phase separation and electrolyser technologies to support future human spaceflight architectures.

The Allam power cycle is a groundbreaking elevated-pressure power generation unit that utilizes oxygen and fossil fuels to generate low-cost electricity while capturing carbon dioxide (CO2) inherently. In this project we utilize the CO2 generated from the Allam cycle as feedstock for a newly envisioned industrial complex dedicated to producing renewable hydrocarbons. The industrial complex (FAAR) comprises four subsystems: (i) a Fischer–Tropsch synthesis plant (FTSP) (ii) an alkaline water electrolysis plant (AWEP) (iii) an Allam power cycle plant (APCP) and (iv) a reverse water-gas shift plant (RWGSP). Through effective material heat and power integration the FAAR complex utilizing 57.1% renewable energy for its electricity needs can poly-generate sustainable hydrocarbons (C1–C30) pure hydrogen and oxygen with near-zero emissions from natural gas and water. Economic analysis indicates strong financial performance of the development with an internal rate of return (IRR) of 18% a discounted payback period of 8.7 years and a profitability index of 2.39. The complex has been validated through rigorous modeling and simulation using Aspen Plus version 14 including sensitivity analysis.

Pilot projects to generate hydrogen using proton exchange membrane (PEM) electrolyzers coupled to nuclear power plants (NPPs) began in 2022 with further developments anticipated over the next decade. However the co-location of electrolyzers with NPPs requires an understanding and mitigation of potential risks. In this work we identify and rank failure contributors for a 1 MW PEM electrolysis system. We used fault trees to define the component failure logic parameterized them with generic data and calculated failure frequencies and minimal cut sets for four top events: hydrogen release oxygen release nitrogen release and hydrogen and oxygen mixing. We use risk reduction worth importance measures to determine the most risk-significant components. The results provide insight into primary risk drivers in PEM electrolyzer systems and provide the foundational steps towards quantitative risk assessment of large-scale PEM electrolyzers at NPPs. The results include recommended riskmitigation actions include recommendations about design maintenance and monitoring strategies.

Hydrogen energy generation faces challenges in efficiency and economic viability due to reliance on scarce noble metal catalysts. This study aimed to develop platinum-doped nickel-iron metal-organic framework (Pt-NiFe-MOF) catalysts with controlled metal ratios and pore architecture for enhanced water electrolysis. The NiFe-MOF framework was first synthesized via a solvothermal method which was then subjected to post-synthetic modification to introduce controlled platinum loadings (0.5- 2.0 wt%). The pore structure was tuned using a mixed-linker strategy (H₄DOBDC ratios 1:0 to 1:1). Catalysts were characterized using PXRD HRTEM BET XPS and ICP-OES techniques. Electrochemical performance was analyzed in 1.0 M KOH. A custom-designed integrated electrolysis system at 75 °C assessed practical performance. The Pt-NiFe-MOF-1.0 catalyst with H₄DOBDC ratio of 1:0.5 achieved remarkable effectiveness requiring overpotentials of only 253 mV for OER and 58 mV for HER when operating at 10 mA/cm². This catalyst featured an optimal pore diameter of 4.2 nm and surface area of 1325 m²/g. DFT calculations revealed platinum incorporation created synergistic effects by modifying hydrogen binding energies. Furthermore DFT calculations and XPS analysis revealed that the role of platinum in the OER is not direct catalysis but rather a powerful electronic modulation effect; Pt dopants withdraw electron density from adjacent Ni and Fe centers promoting the formation of higher-valent Ni³⁺/Fe³⁺ species that are intrinsically more active and lowering the energy barrier for the rate-determining O-O bond formation step. The integrated system achieved 1.62V at 100 mA/cm² with 75.8% energy efficiency maintaining stability for 200 h with 15–30 times lower precious metal loading than conventional systems. Strategic incorporation of low platinum concentrations within optimized NiFe-MOF structures significantly enhances water electrolysis performance while maintaining economic viability advancing development of industrial-scale hydrogen generation systems.