Production & Supply Chain

The increasing demand for energy and commodities has led to escalating greenhouse gas emissions the chief of which is represented by carbon dioxide (CO2). Blue hydrogen (H2) a lowcarbon hydrogen produced from natural gas with carbon capture technologies applied has been suggested as a possible alternative to fossil fuels in processes with hard-to-abate emission sources including refining chemical petrochemical and transport sectors. Due to the recent international directives aimed to combat climate change even existing hydrogen plants should be retrofitted with carbon capture units. To optimize the process economics of such retrofit it has been proposed to remove CO2 from the pressure swing adsorption (PSA) tail gas to exploit the relatively high CO2 concentration. This study aimed to design and numerically investigate a vacuum pressure swing adsorption (VPSA) process capable of capturing CO2 from the PSA tail gas of an industrial steam methane reforming (SMR)-based hydrogen plant using NaX zeolite adsorbent. The effect of operating conditions such as purge-to-feed ratio and desorption pressure were evaluated in relation to CO2 purity CO2 recovery bed productivity and specific energy consumption. We found that conventional cycle configurations namely a 2-bed 4-step Skarstrom cycle and a 2-bed 6-step modified Skarstrom cycle with pressure equalization were able to concentrate CO2 to a purity greater than 95% with a CO2 recovery of around 77% and 90% respectively. Therefore the latter configuration could serve as an efficient process to decarbonize existing hydrogen plants and produce blue H2.

The presented research focuses on an optimization design of a catalyst distribution inside a small-scale methane/steam reforming reactor. A genetic algorithm was used for the multiobjective optimization which included the search for an optimum of methane conversion rate and a minimum of the difference between highest and lowest temperatures in the reactor. For the sake of computational time the maximal number of the segment with different catalyst densities was set to be thirty in this study. During the entire optimization process every part of the reactor could be filled either with a catalyst material or non-catalytic metallic foam. In both cases the porosity and pore size was also specified. The impact of the porosity and pore size on the active reaction surface and permeability was incorporated using graph theory and three-dimensional digital material representation. Calculations start with the generation of a random set of possible reactors each with a different catalyst distribution. The algorithm calls reforming simulation over each of the reactors and after obtaining concentration and temperature fields the algorithms calculated fitness function. The properties of the best reactors are combined to generate a new population of solutions. The procedure is repeated and after meeting the coverage criteria the optimal catalyst distribution was proposed. The paper is summarized with the optimal catalyst distribution for the given size and working conditions of the system.

Excessive consumption of fossil fuels has led to depletion of reserves and environmental crises. Therefore turning to clean energy sources is essential. However these energy sources are intermittent in nature and have problems meeting long-term energy demand. The option suggested by the researchers is to use hybrid energy systems. The aim of this paper is provide the conceptual configuration of a novel energy cycle based on clean energy resources. The novel energy cycle is composed of a wind turbine solar photovoltaic field (PV) an alkaline fuel cell (AFC) a Stirling engine and an electrolyzer. Solar PV and wind turbine convert solar light energy and wind kinetic energy into electricity respectively. Then the generated electricity is fed to water electrolyzer. The electrolyzer decomposes water into oxygen and hydrogen gases by receiving electrical power. So the fuel cell inlets are provided. Next the AFC converts the chemical energy contained in hydrogen into electricity during electrochemical reactions with by-product (heat). The purpose of the introduced cycle is to generate electricity and hydrogen fuel. The relationships defined for the components of the proposed cycle are novel and is examined for the first time. Results showed that the output of the introduced cycle is 10.5 kW of electricity and its electrical efficiency is 56.9%. In addition the electrolyzer uses 9.9 kW of electricity to produce 221.3 grams per hour of hydrogen fuel. The share of the Stirling engine in the output power of the cycle is 9.85% (1033.7 W) which is obtained from the dissipated heat of the fuel cell. In addition wind turbine is capable of generating an average of 4.1 kW of electricity. However 238.6 kW of cycle exergy is destroyed. Two different scenarios are presented for solar field design.

Hydrogen (H₂) is a promising renewable energy source that can replace fossil fuels since it can solve several environmental and economic issues. However the widespread usage of H₂ is constrained by its storage and safety issues. Many researchers consider solid materials with an excellent capacity for H₂ storage and generation as the solution for most H₂-related issues. Among solid materials ammonia borane (abbreviated hereafter as AB) is considered one of the best hydrogen storage materials due to its extraordinary H₂ content and small density. However the process must be conducted in the presence of efficient catalysts to obtain a reasonable amount of generated H₂. Electrospun nanofibrous catalysts are a new class of efficient catalysts that involves the usage of polymers. Here a comprehensive review of the ceramic-supported electrospun NF catalysts for AB hydrolysis is presented with a special focus on catalytic and photolytic performance and preparation steps. Photocatalytic AB hydrolysis was discussed in detail due to its importance and promising results. AB photocatalytic hydrolysis mechanisms under light were also explained. Electrospun catalysts show excellent activity for AB hydrolysis with good recyclability. Kinetics studies show that the AB hydrolysis reaction is independent of AB concentration and the first-order reaction of NF catalysts.

In the future hydrogen (H2) will play a significant role in the sustainable supply of energy and raw materials to various sectors. Therefore the electrolysis of water required for industrial‐ scale H2 production represents a key component in the generation of renewable electricity. Within the scope of fundamental research work on cell components for polymer electrolyte membrane (PEM) electrolyzers and application‐oriented living labs an MW electrolysis system was used to further improve industrial‐scale electrolysis technology in terms of its basic structure and systems‐ related integration. The planning of this work as well as the analytical and technical approaches taken along with the essential results of research and development are presented herein. The focus of this study is the test facility for a megawatt PEM electrolysis stack with the presentation of the design processing and assembly of the main components of the facility and stack.

Hydrogen produced from renewable energy has the potential to decarbonize parts of the transport sector and many other industries. For a sustainable replacement of fossil energy carriers both the environmental and economic performance of its production are important. Here the solar thermochemical hydrogen pathway is characterized with a techno-economic and life-cycle analysis. Assuming a further increase of conversion efficiency and a reduction of investment costs it is found that hydrogen can be produced in the United States of America at costs of 2.1–3.2 EUR/kg (2.4–3.6 USD/kg) at specific greenhouse gas emissions of 1.4 kg CO₂-eq/kg. A geographical potential analysis shows that a maximum of 8.4 × 1011 kg per year can be produced which corresponds to about twelve times the current global and about 80 times the current US hydrogen production. The best locations are found in the Southwest of the US which have a high solar irradiation and short distances to the sea which is beneficial for access to desalinated water. Unlike for petrochemical products the transport of hydrogen could potentially present an obstacle in terms of cost and emissions under unfavorable circumstances. Given a large-scale deployment low-cost transport seems however feasible.

Hydrogen can be generated in situ within reservoirs containing hydrocarbons through chemical reactions. This technology could be a possible solution for low-emission hydrogen production due to of simultaneous CO2 storage. In gas fields it is possible to carry out the catalytic methane conversion (CMC) if sufficient amounts of steam catalyst and heat are ensured in the reservoir. There is no confirmation of the CMC’s feasibility at relatively low temperatures in the presence of core (reservoir rock) material. This study introduces the experimental results of the first part of the research on in situ hydrogen generation in the Promyslovskoye gas field. A set of static experiments in the autoclave reactor were performed to study the possibility of hydrogen generation under reservoir conditions. It was shown that CMC can be realized in the presence of core and ex situ prepared Ni-based catalyst under high pressure up to 207 atm but at temperatures not lower than 450 ◦C. It can be concluded that the crushed core model improves the catalytic effect but releases carbon dioxide and light hydrocarbons which interfere with the hydrogen generation. The maximum methane conversion rate to hydrogen achieved at 450 ◦C is 5.8%

Hydrogen as a strategy clean fuel is receiving more and more attention recently in China in addition to the policy emphasis on H2. In this work we conceive of a hydrogen production process based on a chemical regenerative coal gasification. Instead of using a lumped coal gasification as is traditional in the H2 production process herein we used a two-step gasification process that included coking and char-steam gasification. The sensible heat of syngas accounted for 15–20% of the total energy of coal and was recovered and converted into chemical energy of syngas through thermochemical reactions. Moreover the air separation unit was eliminated due to the adoption of steam as oxidant. As a result the efficiency of coal to H2 was enhanced from 58.9% in traditional plant to 71.6% in the novel process. Further the energy consumption decreased from 183.8 MJ/kg in the traditional plant to 151.2 MJ/kg in the novel process. The components of syngas H2 and efficiency of gasification are herein investigated through experiments in fixed bed reactors. Thermodynamic performance is presented for both traditional and novel coal to hydrogen plants.

Hydrogen produced in a polymer electrolyte membrane (PEM) electrolyzer must be stored under high pressure. It is discussed whether the gas should be compressed in subsequent gas compressors or by the electrolyzer. While gas compressor stages can be reduced in the case of electrochemical compression safety problems arise for thin membranes due to the undesired permeation of hydrogen across the membrane to the oxygen side forming an explosive gas. In this study a PEM system is modeled to evaluate the membrane-specific total system efficiency. The optimum efficiency is given depending on the external heat requirement permeation cell pressure current density and membrane thickness. It shows that the heat requirement and hydrogen permeation dominate the maximum efficiency below 1.6 V while above the cell polarization is decisive. In addition a pressure-optimized cell operation is introduced by which the optimum cathode pressure is set as a function of current density and membrane thickness. This approach indicates that thin membranes do not provide increased safety issues compared to thick membranes. However operating an N212-based system instead of an N117-based one can generate twice the amount of hydrogen at the same system efficiency while only one compressor stage must be added.

A methodology for assessing the sustainability of hydrogen production using solid fuels is introduced in which three sustainability dimensions (ecological sociological and technological) are considered along with ten indicators for each dimension. Values for each indicator are assigned on a 10-point scale based on a high of 1 and a low of 0 depending on the characteristic of the criteria associated with each element or process utilizing data reported in the literature. An illustrative example is presented to compare two solid fuels for hydrogen production: coal and biomass. The results suggest that qualitative sustainability indicators can be reasonably defined based on evaluations of system feasibility and that adequate flexibility and comprehensiveness is provided through the use of ten indicators for each of the dimensions for every process or element involved in hydrogen production using solid fuels. Also the assessment index values suggest that biomasses have better sustainability than coals and that it may be advantageous to use coals in combination with biomass to increase their ecological and social sustainability. The sustainability assessment methodology can be made increasingly quantitative and is likely extendable to other energy systems but additional research and development is needed to lead to a more fully developed approach.