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Future of Hydrogen as an Alternative Fuel for Next-Generation Industrial Applications; Challenges and Expected Opportunities
Jun 2022
Publication
A general rise in environmental and anthropogenically induced greenhouse gas emissions has resulted from worldwide population growth and a growing appetite for clean energy industrial outputs and consumer utilization. Furthermore well-established advanced and emerging countries are seeking fossil fuel and petroleum resources to support their aviation electric utilities industrial sectors and consumer processing essentials. There is an increasing tendency to overcome these challenging concerns and achieve the Paris Agreement’s priorities as emerging technological advances in clean energy technologies progress. Hydrogen is expected to be implemented in various production applications as a fundamental fuel in future energy carrier materials development and manufacturing processes. This paper summarizes recent developments and hydrogen technologies in fuel refining hydrocarbon processing materials manufacturing pharmaceuticals aircraft construction electronics and other hydrogen applications. It also highlights the existing industrialization scenario and describes prospective innovations including theoretical scientific advancements green raw materials production potential exploration and renewable resource integration. Moreover this article further discusses some socioeconomic implications of hydrogen as a green resource.
Optimized Configuration and Operating Plan for Hydrogen Refueling Station with On-Site Electrolytic Production
Mar 2022
Publication
Hydrogen refueling stations (HRSs) are critical for the popularity of hydrogen vehicles (fuel cell electric vehicles—FCEVs). However due to high installation investment and operating costs the proliferation of HRSs is difficult. This paper studies HRSs with on-site electrolytic production and hydrogen storage devices and proposes an optimization method to minimize the total costs including both installation investment and operating costs (OPT-ISL method). Moreover to acquire the optimization constraints of hydrogen demand this paper creatively develops a refueling behavior simulation method for different kinds of FCEVs and proposes a hydrogen-demand estimation model to forecast the demand with hourly intervals for HRS. The Jensen–Shannon divergence is applied to verify the accuracy of the hydrogen-demand estimation. The result: 0.029 is much smaller than that of the estimation method in reference. Based on the estimation results and peak-valley prices of electricity from the grid a daily hydrogen generation plan is obtained as well as the optimal capacities of electrolyzers and storage devices. As for the whole costs compared with previous configuration methods that only consider investment costs or operating costs the proposed OPT-ISL method has the least 8.1 and 10.5% less respectively. Moreover the proposed OPT-ISL method shortens the break-even time for HRS from 11.1 years to 7.8 years a decrease of 29.7% so that the HRS could recover its costs in less time.
Temperature Effect on the Mechanical Properties of Liner Materials used for Type IV Hydrogen Storage Tanks
Sep 2021
Publication
Type IV hydrogen storage tanks play an important role in hydrogen fuel cell vehicles (HFCVs) due to their superiority of lightweight good corrosion and fatigue resistance. It is planned to be used between -40℃ and 85℃ at which the polymer liner may have a degradation of mechanical properties and buckling collapse. This demand a good performance of liner materials in that temperature range. In this article the temperature effect on mechanical properties of polyamide 6 (PA6) liner material including specimens with weld seam was investigated via the stress-strain curve (S-S curve) macroscopic and microscopic morphology. Considering that the mechanical properties will change after the liner molding process this test takes samples directly from the liner. Results show that the tensile strength and tensile modulus increased by 2.46 times and 10.6 times respectively with the decrease of temperature especially in the range from 50℃ to -90℃. For the elongation at break and work of fracture they do not monotonously increase with the temperature up. Both of them reduce when the temperature rises from 20°C to 50°C especially for the work of fracture decreasing by 63%. The weld seam weakens the mechanical properties and the elongation at break and work of fracture are more obvious which are greater than 40% at each temperature. In addition the SEM images indicate that the morphology of fracture surface at -90°C is different from that at other temperatures which is a sufficient evidence of toughness reducing in low temperature.
Industrial Decarbonization Pathways: The Example of the German Glass Industry
Nov 2022
Publication
Mitigating anthropogenic climate change and achieving the Paris climate goals is one of the greatest challenges of the twenty-first century. To meet the Paris climate goals sector-specific transformation pathways need to be defined. The different transformation pathways are used to hypothetically quantify whether a defined climate target is achievable or not. For this reason a bottom-up model was developed to assess the extent of selected industrial decarbonization options compared to conventionally used technologies from an emissions perspective. Thereby the bottom-up model is used to analyze the German container and flat glass industries as an example. The results show that no transformation pathway can be compatible with the 1.5 °C based strict carbon dioxide budget target. Even the best case scenario exceeds the 1.5 °C based target by approximately +200%. The 2 °C based loose carbon dioxide budget target is only achievable via fuel switching the complete phase-out from natural gas to renewable energy carriers. Furthermore the results of hydrogen for flat glass production demonstrate that missing investments in renewable energy carriers may lead to the non-compliance with actually achievable 2 °C based carbon dioxide budget targets. In conclusion the phase-out from natural gas to renewable energies should be executed at the end of the life of any existing furnace and process emissions should be avoided in the long term to contribute to 1.5 °C based strict carbon dioxide budget target.
Synergies between Renewable Energy and Flexibility Investments: A Case of a Medium-Sized Industry
Nov 2021
Publication
Climate and energy policies are tools used to steer the development of a sustainable economy supplied by equally sustainable energy systems. End-users should plan their investments accounting for future policies such as incentives for system-oriented consumption emission prices and hydrogen economy to ensure long-term competitiveness. In this work the utilization of variable renewable energy and flexibility potentials in a case study of an an aggregate industry is investigated. An energy concept considering PV and battery expansion flexible production fuel cell electric trucks (FCEV) and hydrogen production is proposed and analysed under expected techno-economic conditions and policies of 2030 using an energy system optimization model. Under this concept total costs and emissions are reduced by 14% and 70% respectively compared to the business-as-usual system. The main benefit of PV investment is the lowered electricity procurement. Flexibility from schedule manufacturing and hydrogen production increases not only the self-consumption of PV generation from 51% to 80% but also the optimal PV capacity by 41%. Despite the expected cost reduction and efficiency improvement FCEV is still not competitive to diesel trucks due to higher investment and fuel prices i.e. its adoption increases the costs by 8%. However this is resolved when hydrogen can be produced from own surplus electricity generation. Our findings reveal synergistic effects between different potentials and the importance of enabling local business models e.g. regional hydrogen production and storage services. The SWOT analysis of the proposed concept shows that the pursuit of sustainability via new technologies entails new opportunities and risks. Lastly end-users and policymakers are advised to plan their investments and supports towards integration of multiple application consumption sectors and infrastructure.
Renewable Hydrogen Production from Butanol Steam Reforming over Nickel Catalysts Promoted by Lanthanides
Oct 2021
Publication
Hydrogen is mainly produced by steam reforming of natural gas a non-renewable resource. Alternative and renewable routes for hydrogen production play an important role in reducing dependence on oil and minimizing the emission of greenhouse gases. In this work butanol a model compound of bio-oil was employed for hydrogen production by steam reforming. The reaction was evaluated for 30 h in a tubular quartz reactor at 500 ◦C atmospheric pressure GHSV of 500000 h−1 and an aqueous solution feed of 10% v/v butanol. For this reaction catalysts with 20 wt.% NiO were prepared by wet impregnation using three supports: γ-alumina and alumina modified with 10 wt.% of cerium and lanthanum oxides. Both promoters increased the reduction degree of the catalysts and decreased catalyst acidity which is closely related to coke formation and deactivation. Ni/La2O3– Al2O3 presented a higher nickel dispersion (14.6%) which combined with other properties led to a higher stability higher mean hydrogen yield (71%) and lower coke formation per mass (56%). On the other hand the nonpromoted catalyst suffered a significant deactivation associated with coke formation favored by its highest acidity (3.1 µmol m−2 ).
Chemical Inhibition of Premixed Hydrogen-air Flames: Experimental Investigation using a 20-litre Vessel
Sep 2021
Publication
Throughout the history of the mining petroleum process and nuclear industries continuous efforts have been made to develop and improve measures to prevent and mitigate accidental explosions. Over the coming decades energy systems are expected to undergo a transition towards sustainable use of conventional hydrocarbons and an increasing share of renewable energy sources in the global energy mix. The variable and intermittent supply of energy from solar and wind points to energy systems based on hydrogen or hydrogen-based fuels as the primary energy carriers. However the safety-related properties of hydrogen imply that it is not straightforward to achieve and document the same level of safety for hydrogen systems compared to similar systems based on established fuels such as petrol diesel and natural gas. Compared to the conventional fuels hydrogen-air mixtures have lower ignition energy higher combustion reactivity and a propensity to undergo deflagration-to-detonation-transition (DDT) under certain conditions. To achieve an acceptable level of safety it is essential to develop effective measures for mitigating the consequences of hydrogen explosions in systems with certain degree of congestion and confinement. Extensive research over the last decade have demonstrated that chemical inhibition or partial suppression can be used for mitigating the consequences of vapour cloud explosions (VCEs) in congested process plants. Total and cooperation partners have demonstrated that solid flame inhibitors injected into flammable hydrocarbon-air clouds represent an effective means of mitigating the consequences of VCEs involving hydrocarbons. For hydrogen-air explosions these same chemicals inhibitors have not proved effective. It is however well-known that hydrocarbons can affect the burning velocity of hydrogen-air mixtures greatly. This paper gives an overview over previous work on chemical inhibitors. In addition experiments in a 20-litre vessel have been performed to investigate the effect of combinations of hydrocarbons and alkali salts on hydrogen/air mixtures.
A CFD Analysis of Liquefied Gas Vessel Explosions
Dec 2021
Publication
Hydrogen is one of the most suitable candidates in replacing fossil fuels. However storage issues due to its very low density under ambient conditions are encountered in many applications. The liquefaction process can overcome such issues by increasing hydrogen’s density and thus enhancing its storage capacity. A boiling liquid expanding vapour explosion (BLEVE) is a phenomenon in liquefied gas storage systems. It is a physical explosion that might occur after the catastrophic rupture of a vessel containing a liquid with a temperature above its boiling point at atmospheric pressure. Even though it is an atypical accident scenario (low probability) it should be always considered due to its high yield consequences. For all the above-mentioned reasons the BLEVE phenomenon for liquid hydrogen (LH2) vessels was studied using the CFD methodology. Firstly the CFD model was validated against a well-documented CO2 BLEVE experiment. Secondly hydrogen BLEVE cases were simulated based on tests that were conducted in the 1990s on LH2 tanks designed for automotive purposes. The parametric CFD analysis examined different filling degrees initial pressures and temperatures of the tank content with the aim of comprehending to what extent the initial conditions influence the blast wave. Good agreement was shown between the simulation outcomes and the LH2 bursting scenario tests results.
Spherically Expanding Flame Simulations in Cantera Using a Lagrangian Formulation
Sep 2021
Publication
A Lagrangian-based one-dimensional approach has been developed using Cantera to study the dynamics of spherically expanding flames. The detailed reaction model USC-Mech II has been employed to examine flame propagating in hydrogen-air mixtures. In the first part our approach has been validated against laminar flame speed and Markstein number data from the literature. It was shown that the laminar flame speed was predicted within 5% on average but that discrepancies were observed for the Markstein number especially for rich mixtures. In the second part a detailed analysis of the thermo-chemical dynamics along the path of Lagrangian particles propagating in stretched flames was performed. For mixtures with negative Markstein lengths it was found that at high stretch rates the mixture entering the reaction-dominated period is less lean with respect to the initial mixture than at low stretch rate. This induces a faster rate of chemical heat release and of active radical production which results in a higher flame propagation speed. Opposite effects were observed for mixtures with positive Markstein lengths for which slower flame propagation was observed at high stretch rates compared to low stretch rates."
Why Ultrasonic Gas Leak Detection?
Sep 2021
Publication
Technologies that have traditionally been used in fixed installations to detect hydrogen gas leaks such as Catalytic and Electrochemical Point Sensors have one limitation: in order for a leak to be detected the gas itself must either be in close proximity to the detector or within a pre-defined area. Unfortunately outdoor environmental conditions such as changing wind directions and quick dispersion of the gas cloud from a leaking outdoor installation often cause that traditional gas detection systems may not alert to the presence of gas simply because the gas never reaches the detector. These traditional gas detection systems need to wait for the gas to form a vapor cloud which may or may not ignite and which may or may not allow loss prevention by enabling shutting down the gas facility in time. Ultrasonic Gas Leak Detectors (UGLD) respond at the speed of sound at gas leak initiation unaffected by changing wind directions and dilution of the gas. Ultrasonic Gas Leak Detectors are based on robust microphone technology; they detect outdoor leaks by sensing the distinct high frequency ultrasound emitted by all high pressure gas leaks. With the ultrasonic sensing technology leaking gas itself does not have to reach the sensor – just the sound of the gas leaking. By adding Ultrasonic Gas Leak Detectors for Hydrogen leak detection faster response times and lower operation costs can be obtained.
Monte-Carlo-Analysis of Minimum Burst Requirements for Composite Cylinders for Hydrogen Service
Sep 2021
Publication
For achieving Net Zero-aims hydrogen is an indispensable component probably the main component. For the usage of hydrogen a wide acceptance is necessary which requires trust in hydrogen based on absence of major incidents resulting from a high safety level. Burst tests stand for a type of testing that is used in every test standard and regulation as one of the key issues for ensuring safety in use. The central role of burst and proof test is grown to historical reasons for steam engines and steel vessels but - with respect for composite pressure vessels (CPVs) - not due an extraordinary depth of outcomes. Its importance results from the relatively simple test process with relatively low costs and gets its importance by running of the different test variations in parallel. In relevant test und production standards (as e. g. ECE R134) the burst test is used in at least 4 different meanings. There is the burst test on a) new CPVs and some others b) for determining the residual strength subsequent to various simulations of ageing effects. Both are performed during the approval process on a pre-series. Then there is c) the batch testing during the CPVs production and finally d) the 100% proof testing which means to stop the burst test at a certain pressure level. These different aspects of burst tests are analysed and compared with respect to its importance for the resulting safety of the populations of CPVs in service based on experienced test results and Monte-Carlo simulations. As main criterial for this the expected failure rate in a probabilistic meaning is used. This finally ends up with recommendations for relevant RC&S especially with respect to GTR 13."
AI Agents Envisioning the Future: Forecast-based Operation of Renewable Energy Storage Systems Using Hydrogen with Deep Reinforcement Learning
Feb 2022
Publication
Hydrogen-based energy storage has the potential to compensate for the volatility of renewable power generation in energy systems with a high renewable penetration. The operation of these storage facilities can be optimized using automated energy management systems. This work presents a Reinforcement Learning-based energy management approach in the context of CO2-neutral hydrogen production and storage for an industrial combined heat and power application. The economic performance of the presented approach is compared to a rule-based energy management strategy as a lower benchmark and a Dynamic Programming-based unit commitment as an upper benchmark. The comparative analysis highlights both the potential benefits and drawbacks of the implemented Reinforcement Learning approach. The simulation results indicate a promising potential of Reinforcement Learning-based algorithms for hydrogen production planning outperforming the lower benchmark. Furthermore a novel approach in the scientific literature demonstrates that including energy and price forecasts in the Reinforcement Learning observation space significantly improves optimization results and allows the algorithm to take variable prices into account. An unresolved challenge however is balancing multiple conflicting objectives in a setting with few degrees of freedom. As a result no parameterization of the reward function could be found that fully satisfied all predefined targets highlighting one of the major challenges for Reinforcement Learning -based energy management algorithms to overcome.
Numerical Simulation on Pressure Dynamic Response Characteristics of Hydrogen Systems for Fuel Cell Vehicles
Mar 2022
Publication
A proton exchange membrane fuel cell (PEMFC) is known as one of the most promising energy sources for electric vehicles. A hydrogen system is required to provide hydrogen to the stack in time to meet the flow and pressure requirements according to the power requirements. In this study a 1-D model of a hydrogen system including the fuel cell stack was established. Two modes one with and one without a proportion integration differentiation (PID) control strategy were applied to analyze the pressure characteristics and performance of the PEMFC. The results showed that the established model could be well verified with experimental data. The anode pressure fluctuation with a PID control strategy was more stable which reduced the damage to the fuel cell stack caused by sudden changes of anode pressure. In addition the performance of the stack with the PID control mode was slightly improved. There was an inflection point for hydrogen utilization; the hydrogen utilization rate was higher under the mode without PID control when the current density was greater than 0.4 A/cm2 . What is more a hierarchical control strategy was proposed which made the pressure difference between the anode and cathode meet the stack working requirements and more importantly maintained the high hydrogen utilization of the hydrogen system.
Optimal Dispatch Model for PV-electrolysis Plants in Self-consumption Regime to Produce Green Hydrogen: A Spanish Case Study
May 2022
Publication
The production of green hydrogen from renewable energy by means of water electrolysis is a promising approach to support energy sector decarbonization. This paper presents a techno-economic model of plants with PV sources connected to electrolysis in self-consumption regime that considers the dynamics of electrolysis systems. The model calculates the optimal hourly dispatch of the electrolysis system including the operational states (production standby and idle) the load factor in production and the energy imports and exports to the electricity grid. Results indicate that the model is a useful decision support tool to operate electrolysis plants connected to PV plants in self-consumption regimes with the target of reducing hydrogen production costs.
Design and Analysis of Photovoltaic/wind Operations at MPPT for Hydrogen Production using a PEM Electrolyzer: Towards Innovations in Green Technology
Jul 2023
Publication
In recent times renewable energy systems (RESs) such as Photovoltaic (PV) and wind turbine (WT) are being employed to produce hydrogen. This paper aims to compare the efficiency and performance of PV and WT as sources of RESs to power polymer electrolyte membrane electrolyzer (PEMEL) under different conditions. The study assessed the input/ output power of PV and WT the efficiency of the MPPT controller the calculation of the green hydrogen production rate and the efficiency of each system separately. The study analyzed variable irradiance from 600 to 1000 W/m2 for a PV system and a fixed temperature of 25˚C while for the WT system it considered variable wind speed from 10 to 14 m/s and zero fixed pitch angle. The study demonstrated that the applied controllers were effective fast low computational and highly accurate. The obtained results showed that WT produces twice the PEMEL capacity while the PV system is designed to be equal to the PEMEL capacity. The study serves as a reference for designing PV or WT to feed an electrolyzer. The MATLAB program validated the proposed configurations with their control schemes.
Safety and Other Considerations in the Development of a Hydrogen Fueling Protocol for Heavy-duty Vehicles
Sep 2021
Publication
Several manufacturers are developing heavy duty (HD) hydrogen stations and vehicles as zeroemissions alternatives to diesel and gasoline. In order to meet customer demands the new technology must be comparable to conventional approaches including safety reliability fueling times and final fill levels. For a large HD vehicle with a storage rated to 70 MPa nominal working pressure the goal to meet liquid fuel parity means providing 100 kg of hydrogen in 10 minutes. This paper summarizes the results to date of the PRHYDE project efforts to define the concepts of HD fueling which thereby lays the groundwork for the development of the safe and effective approach to filling these large vehicles. The project starts by evaluating the impact of several different assumptions such as the availability of static vehicle data (e.g. vehicle tank type and volume) and station data (e.g. expected station precooling capability) but also considers using real time dynamic data (e.g. vehicle tank gas temperature and pressure station gas temperature etc.) for optimisation to achieve safety and efficiency improvements. With this information the vehicle or station can develop multiple maps of fill time versus the hydrogen delivery temperature which are used to determine the speed of fueling. This will also allow the station or vehicle to adjust the rate of fueling as the station pre-cooling levels and other conditions change. The project also examines different steps for future protocol development such as communication of data between the vehicle and station and if the vehicle or station is controlling the fueling.
Measurement and Modeling on Hydrogen Jet and Combustion from a Pressurize Vessel
Sep 2021
Publication
Hydrogen safety is an important topic for hydrogen energy application. Unintended hydrogen releases and combustions are potential accident scenarios which are of great interest for developing and updating the safety codes and standards. In this paper hydrogen releases and delayed ignitions were studied.
1921–2021: A Century of Renewable Ammonia Synthesis
Apr 2022
Publication
Synthetic ammonia manufactured by the Haber–Bosch process and its variants is the key to securing global food security. Hydrogen is the most important feedstock for all synthetic ammonia processes. Renewable ammonia production relies on hydrogen generated by water electrolysis using electricity generated from hydropower. This was used commercially as early as 1921. In the present work we discuss how renewable ammonia production subsequently emerged in those countries endowed with abundant hydropower and in particular in regions with limited or no oil gas and coal deposits. Thus renewable ammonia played an important role in national food security for countries without fossil fuel resources until after the mid-20th century. For economic reasons renewable ammonia production declined from the 1960s onward in favor of fossil-based ammonia production. However renewable ammonia has recently gained traction again as an energy vector. It is an important component of the rapidly emerging hydrogen economy. Renewable ammonia will probably play a significant role in maintaining national and global energy and food security during the 21st century.
Metal Hydroborates: From Hydrogen Stores to Solid Electrolyte
Nov 2021
Publication
The last twenty years of an intense research on metal hydroborates as solid hydrogen stores and solid electrolytes are reviewed. It is shown that from the most promising application in hydrogen storage due to their high gravimetric and volumetric capacities the focus has moved to solid electrolytes due to high cation mobility in disordered structures with rotating or tumbling anions-hydroborate clusters. Various strategies of overcoming the strong covalent bonding of hydrogen in hydroborates for hydrogen storage and disordering their structures at room temperature for solid electrolytes are discussed. The important role of crystal chemistry and crystallography knowledge in material design can be read in the cited literature.
Risk Assessment of a Gaseous Hydrogen Fueling Station (GHFs)
Sep 2021
Publication
Promoted by national and European investment plans promoting the use of hydrogen as energy carrier the number of Gaseous Hydrogen Fueling Station (or GHFS) has been growing up quite significantly over the past years. Considering the new possible hazards and the related accidents induced by these installations like seen in 2019 in Norway this paper presents a risk assessment of a typical GHFS using the same methodology as the one required in France by the authorities for Seveso facilities. The fact that a hydrogen fueling station could be used by a public not particularly trained to handle hydrogen underlines the importance of this risk assessment. In this article typical components related to GHFS (dispenser high pressure storage compressor low pressure storage) are listed and the hazard potentials linked to these components and the substances involved are identified. Based on these elements and an accidentology a risk analysis has been conducted in order to identify all accidental situations that could occur. The workflow included a detailed risk assessment consisting in modeling the thermal and explosion effects of all hazardous phenomena and in assessing the probability of occurrence for these scenarios. Regarding possible mitigation measures the study was based on an international benchmark for codes and standards made for GFHS. These preliminary outcomes of this study may be useful for any designer and/or owner of a GFHS.
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