Membrane-Based Hydrogen Production: A Techno-Economic Evaluation of Cost and Feasibility

As the global shift toward a low-carbon economy accelerates, hydrogen is emerging as a crucial energy source. Among conventional methods for hydrogen production, steam methane reforming (SMR), commonly paired with pressure swing adsorption (PSA) for hydrogen purification, stands out due to its established infrastructure and technological maturity. This comprehensive techno-economic analysis focuses on membrane-based hydrogen production, evaluating four configurations, namely SMR, SMR with PSA, SMR with a palladium membrane, and SMR with a ceramic–carbonate membrane coupled with a carbon capture system (CCS). The life cycle cost (LCC) of each configuration was assessed by analyzing key factors, including production rate, hydrogen pricing, equipment costs, and maintenance expenses. Sensitivity analysis was also conducted to identify major cost drivers influencing the LCC, providing insights into the economic and operational feasibility of each configuration. The analysis reveals that SMR with PSA has the lowest LCC and is significantly more cost-efficient than configurations involving the palladium and ceramic–carbonate membranes. SMR with a ceramic–carbonate membrane coupled with CCS also demonstrates the most sensitive to energy variations due to its extensive infrastructure and energy requirement. Sensitivity analysis confirms that SMR with PSA consistently provides the greatest cost efficiency under varying conditions. These findings underscore the critical balance between cost efficiency and environmental considerations in adopting membrane-based hydrogen production technologies.