Publications

With the growing demand for green technologies hydrogen energy devices such as Proton Exchange Membrane (PEM) fuel cells and water electrolysers have received accelerated developments. However the materials and manufacturing cost of these technologies are still relatively expensive which impedes their widespread commercialization. Additive Manufacturing (AM) commonly termed 3D Printing (3DP) with its advanced capabilities could be a potential pathway to solve the fabrication challenges of PEM parts. Herein in this paper the research studies on the novel AM fabrication methods of PEM components are thoroughly reviewed and analysed. The key performance properties such as corrosion and hydrogen embrittlement resistance of the additively manufactured materials in the PEM working environment are discussed to emphasise their reliability for the PEM systems. Additionally the major challenges and required future developments of AM technologies to unlock their full potential for PEM fabrication are identified. This paper provides insights from the latest research developments on the significance of advanced manufacturing technologies in developing sustainable energy systems to address the global energy challenges and climate change effects.

Water electrolysis is the most promising method for efficient production of high purity hydrogen (and oxygen) while the required power input for the electrolysis process can be provided by renewable sources (e.g. solar or wind). The thus produced hydrogen can be used either directly as a fuel or as a reducing agent in chemical processes such as in Fischer–Tropsch synthesis. Water splitting can be realized both at low temperatures (typically below 100 °C) and at high temperatures (steam water electrolysis at 500– 1000 °C) while different ionic agents can be electrochemically transferred during the electrolysis process (OH− H+ O2− ). Singular requirements apply in each of the electrolysis technologies (alkaline polymer electrolyte membrane and solid oxide electrolysis) for ensuring high electrocatalytic activity and long-term stability. The aim of the present article is to provide a brief overview on the effect of the nature and structure of the catalyst–electrode materials on the electrolyzer’s performance. Past findings and recent progress in the development of efficient anode and cathode materials appropriate for large-scale water electrolysis are presented. The current trends limitations and perspectives for future developments are summarized for the diverse electrolysis technologies of water splitting while the case of CO2/H2O co-electrolysis (for synthesis gas production) is also discussed.

The transport of hydrogen in used natural gas pipelines is a strategic key element of a pan-European hydrogen infrastructure. At the same time accurate knowledge of the hydrogen quality is essential in order to be able to address a wide application range. Therefore an experimental investigation was carried out to find out which contaminants enter into the hydrogen from the used natural gas pipelines. Pipeline elements from the high pressure gas grid of Austria were exposed to hydrogen. Steel pipelines built between 1960 and 2018 which were operated with odorised and pure natural gas were examined. The hydrogen was analysed according to requirements of ISO14687: 2019 Grade D measurement standard. The results show that based on age odorization and sediments different contimenants are introduced. Odorants hydrocarbons but also sulphur compounds ammonia and halogenated hydrogen compounds were identified. Sediments are identified as the main source of impurities. However the concentrations of the introduced contaminants were low (6 nmol/mol to 10 μmol/mol). Quality monitoring with a wide range of detection options for different components (sulphur halogenated compounds hydrocarbons ammonia and atmospheric components) is crucial for real operation. The authors deduce that a Grade A hydrogen quality can be safely achieved in real operation.

The utilisation of hydrogen in ships has important potential in terms of achieving the decarbonisation of waterway transport which produces approximately 3% of the world’s total emissions. However the utilisation of hydrogen drives in maritime and inland shipping is conditioned by the efficient and safe storage of hydrogen as an energy carrier on ship decks. Regardless of the type the constructional design and the purpose of the aforesaid vessels the preferred method for hydrogen storage on ships is currently high-pressure storage with an operating pressure of the fuel storage tanks amounting to tens of MPa. Alternative methods for hydrogen storage include storing the hydrogen in its liquid form or in hydrides as adsorbed hydrogen and reformed fuels. In the present article a method for hydrogen storage in metal hydrides is discussed particularly in a certified low-pressure metal hydride storage tank—the MNTZV-159. The article also analyses the 2D heat conduction in a transversal cross-section of the MNTZV-159 storage tank for the purpose of creating a final design of the shape of a heat exchanger (intensifier) that will help to shorten the total time of hydrogen absorption into the alloy i.e. the filling process. Based on the performed 3D calculations for heat conduction the optimisation and implementation of the intensifier into the internal volume of a metal hydride alloy will increase the performance efficiency of the shell heat exchanger of the MNTZV-159 storage tank. The optimised design increased the cooling power by 46.1% which shortened the refuelling time by 41% to 2351 s. During that time the cooling system which comprised the newly designed internal heat transfer intensifier was capable of eliminating the total heat from the surface of the storage tank thus preventing a pressure increase above the allowable value of 30 bar.

The future of a carbon-free society relies on the alignment of the intermittent production of renewable energy with our continuous and increasing energy demands. Long-term energy storage in molecules with high energy content and density such as ammonia can act as a buffer versus short-term storage (e.g. batteries). In this paper we demonstrate that the Haber–Bosch ammonia synthesis loop can indeed enable a second ammonia revolution as energy vector by replacing the CO2 intensive methane-fed process with hydrogen produced by water splitting using renewable electricity. These modifications demand a redefinition of the conventional Haber–Bosch process with a new optimisation beyond the current one which was driven by cheap and abundant natural gas and relaxed environmental concerns during the last century. Indeed the switch to electrical energy as fuel and feedstock to replace fossil fuels (e.g. methane) will lead to dramatic energy efficiency improvements through the use of high efficiency electrical motors and complete elimination of direct CO2 emissions. Despite the technical feasibility of the electrically-driven Haber–Bosch ammonia the question still remains whether such revolution will take place. We reveal that its success relies on two factors: increased energy efficiency and the development of small-scale distributed and agile processes that can align to the geographically isolated and intermittent renewable energy sources. The former requires not only higher electrolyser efficiencies for hydrogen production but also a holistic approach to the ammonia synthesis loop with the replacement of the condensation separation step by alternative technologies such as absorption and catalysis development. Such innovations will open the door to moderate pressure systems the development and deployment of novel ammonia synthesis catalysts and even more importantly the opportunity for integration of reaction and separation steps to overcome equilibrium limitations. When realised green ammonia will reshape the current energy landscape by directly replacing fossil fuels in transportation heating electricity etc. and as done in the last century food.

Distributed waste-to-hydrogen (WtH) systems are a potential solution to tackle the dual challenges of sustainable waste management and zero emission transport. Here we propose a concept of distributed WtH systems based on gasification and fermentation to support hydrogen fuel cell buses in Glasgow. A variety of WtH scenarios were configured based on biomass waste feedstock hydrogen production reactors and upstream and downstream system components. A cost-benefit analysis (CBA) was conducted to compare the economic feasibility of the different WtH systems with that of the conventional steam methane reforming-based method. This required the curation of a database that included inter alia direct cost data on construction maintenance operations infrastructure and storage along with indirect cost data comprising environmental impacts and externalities cost of pollution carbon taxes and subsidies. The levelized cost of hydrogen (LCoH) was calculated to be 2.22 GB P/kg for municipal solid waste gasification and 2.02 GB P/kg for waste wood gasification. The LCoHs for dark fermentation and combined dark and photo fermentation systems were calculated to be 2.15 GB P/kg and 2.29 GB P/kg. Sensitivity analysis was conducted to identify the most significant influential factors of distributed WtH systems. It was indicated that hydrogen production rates and CAPEX had the largest impact for the biochemical and thermochemical technologies respectively. Limitations including high capital expenditure will require cost reduction through technical advancements and carbon tax on conventional hydrogen production methods to improve the outlook for WtH development.

Wind and solar energy are the important renewable energy sources while their inherent natures of random and intermittent also exert negative effect on the electrical grid connection. As one of multiple energy complementary route by adopting the electrolysis technology the wind-solar-hydrogen hybrid system contributes to improving green power utilization and reducing its fluctuation. Therefore the moving average method and the hybrid energy storage module are proposed which can smooth the wind-solar power generation and enhance the system energy management. Moreover the optimization of system capacity configuration and the sensitive analysis are implemented by the MATLAB program platform. The results indicate that the 10-min grid-connected volatility is reduced by 38.7% based on the smoothing strategy and the internal investment return rate can reach 13.67% when the electricity price is 0.04 $/kWh. In addition the annual coordinated power and cycle proportion of the hybrid energy storage module are 80.5% and 90% respectively. The developed hybrid energy storage module can well meet the annual coordination requirements and has lower levelized cost of electricity. This method provides reasonable reference for designing and optimizing the wind-solar-hydrogen complementary system.

The hydrogen economy is receiving increasing attention as a complement to electrification in the global energy transition. Clean hydrogen production is often viewed as a competition between natural gas reforming with CO2 capture and electrolysis using renewable electricity. However solid fuel gasification with CO2 capture presents another viable alternative especially when considering the potential of biomass to achieve negative CO2 emissions. This study investigates the techno-economic potential of hydrogen production from large-scale coal/ biomass co-gasification plants with CO2 capture. With a CO2 price of 50 €/ton the benchmark plant using commercially available technologies achieved an attractive hydrogen production cost of 1.78 €/kg with higher CO2 prices leading to considerable cost reductions. Advanced configurations employing hot gas clean-up membrane-assisted water-gas shift and more efficient gasification with slurry vaporization and a chemical quench reduced the hydrogen production cost to 1.50–1.62 €/kg with up to 100% CO2 capture. Without contingencies added to the pre-commercial technologies the lowest cost reduces to 1.43 €/kg. It was also possible to recover waste heat in the form of hot water at 120 ◦C for district heating potentially unlocking further cost reductions to 1.24 €/kg. In conclusion gasification of locally available solid fuels should be seriously considered next to natural gas and electrolysis for supplying the emerging hydrogen economy.

The widespread production and use of hydrogen (H2) requires safe handling due to its wide range of flammability and low ignition energy. In confined and semi-confined areas such as garages and tunnels a hydrogen leak will create a potential accumulation of flammable gases. Hence forced ventilation is required in such confined spaces to prevent hydrogen hazards. However this practice may incur higher operating costs and could become ineffective during a power outage. Passive Autocatalytic Recombiners (PARs) are defined as safety devices for preventing hydrogen accumulation in confined spaces. PARs have been widely adopted for hydrogen mitigation in nuclear containment buildings in worst case accident scenarios where forced ventilation is not feasible. PARs are equipped with catalyst plates that self-start due to hydrogen reacting with oxygen at relatively low concentrations (<2 vol. % H2 in air). The heat generated from the reaction creates a self-sustained flow continuously supplying the catalyst surface with fresh hydrogen and oxygen. In this study a 2D transient numerical model has been developed in COMSOL Multiphysics to simulate the operation of PARs. The model was used to analyze the effect of surface reactions on the catalyst temperature flow dynamics self-start behaviour forced versus natural convective flow and steady-state hydrogen recombination rates. The model was also used to simulate carbon monoxide poisoning and its influence on the catalyst performance. Experimental data were used for model calibration and validation showing good agreement for different conditions. Overall the model provides novel insights into PARs operation such as radiation and poisoning effects on the catalyst plate. As a next step assessment of the effectiveness of PARs is underway to mitigate hydrogen hazards in selected confined and semi-confined areas including nuclear and non-nuclear applications.

The production of fat steel products is commonly linked to highly integrated sites which include hot metal generation via the blast furnace basic oxygen furnace (BOF) continuous casting and subsequent hot-rolling. In order to reach carbon neutrality a shift away from traditional carbon-based metallurgy is required within the next decades. Direct reduction (DR) plants are capable to support this transition and allow even a stepwise reduction in CO2 emissions. Nevertheless the implementation of these DR plants into integrated metallurgical plants includes various challenges. Besides metallurgy product quality and logistics special attention is given on future energy demand. On the basis of carbon footprint methodology (ISO 14067:2019) diferent scenarios of a stepwise transition are evaluated and values of possible CO2equivalent (CO2eq) reduction are coupled with the demand of hydrogen electricity natural gas and coal. While the traditional blast furnace—BOF route delivers a surplus of electricity in the range of 0.7 MJ/kg hot-rolled coil; this surplus turns into a defcit of about 17 MJ/ kg hot-rolled coil for a hydrogen-based direct reduction with an integrated electric melting unit. On the other hand while the product carbon footprint of the blast furnace-related production route is 2.1 kg CO2eq/kg hot-rolled coil; this footprint can be reduced to 0.76 kg CO2eq/kg hot-rolled coil for the hydrogen-related route provided that the electricity input is from renewable energies. Thereby the direct impact of the processes of the integrated site can even be reduced to 0.15 kg CO2eq/ kg hot-rolled coil. Yet if the electricity input has a carbon footprint of the current German or European electricity grid mix the respective carbon footprint of hot-rolled coil even increases up to 3.0 kg CO2eq/kg hot-rolled coil. This underlines the importance of the availability of renewable energies.