Production & Supply Chain

This study presents an enhancement to the Switch optimization model for hydrogen energy planning by integrating the capability to consider the construction and operation of hydrogen electrolysis plants and the operation of water distribution systems. This integration was achieved through the addition of two new modules and their effectiveness is demonstrated through their application in a case study for Durham region. The study highlights the significance of incorporating water distribution systems into energy planning demonstrating how optimal locations for hydrogen plants can significantly influence water and power demand as well as alter the total operating costs. The enhanced Switch model showcases its improved capability to assist policymakers and stakeholders in transitioning towards a sustainable energy future.

At present the energy shortage and environmental pollution are the burning global issues. For centuries fossil fuels have been used to meet worldwide energy demand. However thousands of tons of greenhouse gases are released into the atmosphere when fossil fuels are burned contributing to global warming. Therefore green energy must replace fossil fuels and hydrogen is a prime choice. Photocatalytic water splitting (PWS) under solar irradiation could address energy and environmental problems. In the past decade solar photocatalysts have been used to manufacture sustainable fuels. Scientists are working to synthesize a reliable affordable and light-efficient photocatalyst. Developing efficient photocatalysts for water redox reactions in suspension is a key to solar energy conversion. Semiconductor nanoparticles can be used as photocatalysts to accelerate redox reactions to generate chemical fuel or electricity. Carbon materials are substantial photocatalysts for total WS under solar irradiation due to their high activity high stability low cost easy production and structural diversity. Carbon-based materials such as graphene graphene oxide graphitic carbon nitride fullerenes carbon nanotubes and carbon quantum dots can be used as semiconductors photosensitizers cocatalysts and support materials. This review comprehensively explains how carbon-based composite materials function as photocatalytic semiconductors for hydrogen production the water-splitting mechanism and the chemistry of redox reactions. Also how heteroatom doping defects and surface functionalities etc. can influence the efficiency of carbon photocatalysts in H2 production. The challenges faced in the PWS process and future prospects are briefly discussed.

Low-carbon hydrogen can play a significant role in decarbonizing the world. Hydrogen is currently mainly produced from fossil sources requiring additional CO2 capture to decarbonize which energy intense and costly. In a recent Green Energy & Environment paper Cheng and Di et al. proposed a novel integration process referred to as SECLRHC to generate high-purity H2 by in-situ separation of H2 and CO without using any additional separation unit. Theoretically the proposed process can essentially achieve the separation of C and H in gaseous fuel via a reconfigured reaction process and thus attaining high-purity hydrogen of ∼99% as well as good carbon and hydrogen utilization rates and economic feasibility. It displays an optimistic prospect that industrial decarbonization is not necessarily expensive as long as a suitable CCS measure can be integrated into the industrial manufacturing process.

The economic and ecological production of green hydrogen by water electrolysis is one of the major challenges within Carbon2Chem and other power-to-X projects. This paper presents an evaluation of the different water electrolysis technologies with respect to their specific energy demand carbon footprint and the forecast production costs in 2030. From a current perspective alkaline water electrolysis is evaluated as the most favorable technology for the cost-effective production of low-carbon hydrogen with fluctuating renewables.

On this episode of EAH we sat down with Alejandro Oyarce Barnett Chief Technology Officer and Co-Founder at Hystar. Hystar is a technology-focused company specializing in PEM electrolysers for hydrogen production using renewable energy. The company got its start as a spin-off from SINTEF one of Europe’s largest independent research organizations and has raised private funding so the company can focus on production of its high-efficiency PEM units and keep pace with demand for hydrogen generation capacity. Hystar announced on January 11 2023 that the company has closed a Series B funding round of USD 26mn to rapidly scale-up to full commercial operations with an automated GW-capacity production line by 2025.  Alejandro joined us to discuss in more detail the origins of Hystar its technology and the mission at the core of the company.

The podcast can be found on their website.

On today’s episode of Everything About Hydrogen we speak with Raffi Garabedian CEO and Co-Founder of Electric Hydrogen (EH2) a deep decarbonization company pioneering new technology for low cost high efficiency fossil free hydrogen systems. By using electrolyzers many times larger than the industry standard EH2 aims to help eliminate more than 30% of global GHG emissions from difficult to electrify sectors like steel ammonia and freight.

We are excited to learn more from Raffi about the EH2 technology lessons learned by scaling First Solar and what we might expect to see next.

The podcast can be found on their website.

In order to adopt water electrolyzers as a main hydrogen production system it is critical to develop inexpensive and earth-abundant catalysts. Currently both half-reactions in water splitting depend heavily on noble metal catalysts. This review discusses the proton exchange membrane (PEM) water electrolysis (WE) and the progress in replacing the noble-metal catalysts with earth-abundant ones. The efforts within this field for the discovery of efficient and stable earth-abundant catalysts (EACs) have increased exponentially the last few years. The development of EACs for the oxygen evolution reaction (OER) in acidic media is particularly important as the only stable and efficient catalysts until now are noble-metal oxides such as IrOx and RuOx. On the hydrogen evolution reaction (HER) side there is significant progress on EACs under acidic conditions but there are very few reports of these EACs employed in full PEM WE cells. These two main issues are reviewed and we conclude with prospects for innovation in EACs for the OER in acidic environments as well as with a critical assessment of the few full PEM WE cells assembled with EACs.

Ammonia plays a vital role in feeding the world through fertilizer production as well as having other industrial uses. However current ammonia production processes rely heavily on fossil fuels mostly natural gas to generate hydrogen as a feedstock. There is an urgent need to re-design and decarbonise the production process to reduce greenhouse emissions and avoid dependence on volatile gas markets and a depleting resource base. Renewable energy driven electrolysis to generate hydrogen provides a viable pathway for producing carbon-free or green ammonia. However a key challenge associated with producing green ammonia is managing low cost but highly variable wind and solar renewable energy generation for hydrogen electrolysis while maintaining reliable operation of the less flexible ammonia synthesis unit. To date green ammonia production has only been demonstrated at pilot scale and optimising plant configurations and scaling up production facilities is an urgent task. Existing feasibility studies have demonstrated the ability to model and cost green ammonia production pathways that can overcome the technical and economic challenges. However these existing approaches are context specific demonstrating the ability to model and cost green ammonia production for defined locations with set configurations. In this paper we present a modelling framework that consolidates the array of configurations previously studied into a single framework that can be tailored to the location of interest. Our open-source green ammonia modelling and costing tool dynamically simulates the integration of renewable energy with a wide range of balancing power and storage options to meet the flexible demands of the green ammonia production process at hourly time resolution over a year or more. Unlike existing models the open-source implementation of our tool allows it to be used by a potentially wide range of stakeholders to explore their own projects and help guide the upscaling of green ammonia as a pathway for decarbonisation. Using Gladstone in Australia as a case study a 1 million tonne per annum (MMTPA) green ammonia plant is modelled and costed using price assumptions for major equipment in 2030 provided by the Australian Energy Market Operator (AEMO). Using a hybrid (solar PV and wind) renewable energy source and Battery Energy Storage System as balancing technology we estimate a levelized cost of ammonia (LCOA) between 0.69 and 0.92 USD kgNH3 -1 . While greater than historical ammonia production costs from natural gas falling renewables costs and emission reduction imperatives suggest a major future role for green ammonia.

The need for a rapid transformation to low-carbon economies has rekindled hydrogen as a promising energy carrier. Yet the full range of environmental consequences of large-scale hydrogen production remains unclear. Here prospective life cycle analysis is used to compare different options to produce 500 Mt/yr of hydrogen including scenarios that consider likely changes to future supply chains. The resulting environmental and human health impacts of such production levels are further put into context with the Planetary Boundaries framework known human health burdens the impacts of the world economy and the externality-priced production costs that embody the environmental impact. The results indicate that climate change impacts of projected production levels are 3.3–5.4 times higher than the allocated planetary boundary with only green hydrogen from wind energy staying below the boundary. Human health impacts and other environmental impacts are less severe in comparison but metal depletion and ecotoxicity impacts of green hydrogen deserve further attention. Priced-in environmental damages increase the cost most strongly for blue hydrogen (from ∼2 to ∼5 USD/kg hydrogen) while such true costs drop most strongly for green hydrogen from solar photovoltaic (from ∼7 to ∼3 USD/kg hydrogen) when applying prospective life cycle analysis. This perspective helps to evaluate potentially unintended consequences and contributes to the debate about blue and green hydrogen.

The competitiveness of biofuels may be increased by integrating biomass gasification plants with electrolysis units which generate hydrogen to be combined with carbon-rich syngas. This option allows increasing the yield of the final product by retaining a higher amount of biogenic carbon and improving the resilience of the energy sector by favoring electric grid services and sector coupling. This article illustrates a techno-economic comparative analysis of three flexible power and biomass to methanol plants based on different gasification technologies: direct gasification indirect gasification and sorptionenhanced gasification. The design and operational criteria of each plant are conceived to operate both without green hydrogen addition (baseline mode) and with hydrogen addition (enhanced mode) following an intermittent use of the electrolysis system which is turned on when the electricity price allows an economically viable hydrogen production. The methanol production plants include a gasification section syngas cleaning conditioning and compression section methanol synthesis and purification and heat recovery steam cycle to be flexibly operated. Due to the high oxygen demand in the gasifier the direct gasification-based plant obtains a great advantage to be operated between a minimum load to satisfy the oxygen demand at high electricity prices and a maximum load to maximize methanol production at low electricity prices. This allows avoiding large oxygen storages with significant benefits for Capex and safety issues. The analysis reports specific fixed-capital investments between 1823 and 2048 €/kW of methanol output in the enhanced operation and LCOFs between 29.7 and 31.7 €/GJLHV. Economic advantages may be derived from a decrease in the electrolysis capital investment especially for the direct gasification-based plants which employ the greatest sized electrolyzer. Methanol breakeven selling prices range between 545 and 582 €/t with the 2019 reference Denmark electricity price curve and between 484 and 535 €/t with an assumed modified electricity price curve of a future energy mix with increased penetration of intermittent renewables.