Renewable-powered hydrogen economy from Australia's perspective

This article broadly reviews the state-of-the-art technologies for hydrogen production routes, and methods of renewable integration. It outlines the main techno-economic enabler factors for Australia to transform and lead the regional energy market. Two main categories for competitive and commercial-scale hydrogen production routes in Australia are identified: 1) electrolysis powered by renewable, and 2) fossil fuel cracking via steam methane reforming (SMR) or coal gasification which must be coupled with carbon capture and sequestration (CCS). It is reported that Australia is able to competitively lower the levelized cost of hydrogen (LCOH) to a record $(1.88–2.30)/kg_H2 for SMR technologies, and $(2.02–2.47)/kg_H2 for black-coal gasification technologies. Comparatively, the LCOH via electrolysis technologies is in the range of $(4.78–5.84)/kg_H2 for the alkaline electrolysis (AE) and $(6.08–7.43)/kg_H2 for the proton exchange membrane (PEM) counterparts. Nevertheless, hydrogen production must be linked to the right infrastructure in transport-storage-conversion to demonstrate appealing business models.     

Hydrofluoroolefin-based mixed refrigerant for enhanced performance of hydrogen liquefaction process

Hydrogen has the highest gravimetric energy density of all fuels; however, it has a low volumetric energy density, unfavorable for storage and transportation. Hydrogen is usually liquefied to meet the bulk transportation needs. The exothermic interconversion of its spin isomers is an additional activity to an already energy-intensive process. The most significant temperature drop occurs in the precooling cycle (between ?150 °C and up to ?180 °C) and consumes more than 50% of the required energy. To reduce the energy consumption and improve the exergy efficiency of the hydrogen liquefaction process, a new high-boiling component, Hydrofluoroolefin (HFO-1234yf), is added to the precooled mixed refrigerant. As a result, the specific energy consumption of precooling cycle reduces by 41.8%, from 10.15 kWh/kg_LH2 to 5.90 kWh/kg_LH2, for the overall process. The exergy efficiency of the proposed case increases by 43.7%; however, the total equipment cost is also the highest. The inflated cost is primarily due to the added ortho-to-para hydrogen conversion reactor, boosting the para-hydrogen concentration. From the perspective of bulk storage and transportation of liquid hydrogen, the simplicity of design and low energy consumption build a convincing case for considering the commercialization of the process.     

A review on bi/polymetallic catalysts for steam methane reforming

Blue hydrogen production by steam methane reforming (SMR) with carbon capture is by far the most commercialised production method, and with the addition of a simultaneous in-situ CO₂ adsorption process, sorption-enhanced steam methane reforming (SESMR) can further decrease the cost of H₂ production. Ni-based catalysts have been extensively used for SMR because of their excellent activity and relatively low price, but carbon deposition, sulphation, and sintering can lead to catalyst deactivation. One effective solution is to introduce additional metal element(s) to improve the overall performance. This review summarizes recent developments on bi/polymetallic catalysts for SMR, including promoted nickel-based catalysts and other transition metal-based bi/polymetallic materials. The review mainly focuses on experimental studies, but also includes results from simulations to evaluate the synergistic effects of selected metals from an atomic point of view. An outlook is provided for the future development of bi/polymetallic SMR catalysts.     

On the economics of a hydrogen bus fleet powered by a wind park – A case study for Austria

This paper investigates the economics of a fuel cell bus fleet powered by hydrogen produced from electricity generated by a wind park in Austria. The main research question is to simultaneously identify the most economical hydrogen generation business model for the electric utility owning wind power plants and to evaluate the economics of operating a fuel cell bus fleet, with the core objective to minimize the total costs of the overall fuel supply (hydrogen production) and use (bus and operation) system. For that, three possible operation modes of the electrolyzer have been identified and the resulting hydrogen production costs calculated. Furthermore, an in-depth economic analysis of the fuel cell buses as well as the electrolyzer technology has been conducted. Results show that investment costs are the largest cost factor for both technologies. Thus, continuous hydrogen production with the smallest possible electrolyzer is the economically most favorable option. In such an operation mode (power grid), the costs of production per kg/H₂ were the lowest. However, this means that the electrolyzer cannot be solely operated with electricity from the wind park, but is also dependent on the electricity mix from the grid. For fuel cell buses, the future cost development will depend very much on the respective policies and funding programs for the market uptake, as to date, the total cost of use for the fuel cell bus is more than two times higher than the diesel bus. The major final conclusion of this paper is that to make fuel cell electric busses competitive in the next years today severe policy interferences, such as subsidies for these busses as well as electrolyzers and bans for fossil energy, along with investments in the setup of a hydrogen infrastructure, are necessary.     

Refueling-station costs for metal hydride storage tanks on board hydrogen fuel cell vehicles

Refueling costs account for much of the fuel cost for light-duty hydrogen fuel-cell electric vehicles. We estimate cost savings for hydrogen dispensing if metal hydride (MH) storage tanks are used on board instead of 700-bar tanks. We consider a low-temperature, low-enthalpy scenario and a high-temperature, high-enthalpy scenario to bracket the design space. The refueling costs are insensitive to most uncertainties. Uncertainties associated with the cooling duty, coolant pump pressure, heat exchanger (HX) fan, and HX operating time have little effect on cost. The largest sensitivities are to tank pressure and station labor. The cost of a full-service attendant, if the refueling interconnect were to prevent self-service, is the single largest cost uncertainty. MH scenarios achieve $0.71–$0.75/kg-H₂ savings by reducing compressor costs without incurring the cryogenics costs associated with cold-storage alternatives. Practical refueling station considerations are likely to affect the choice of the MH and tank design.     

A strategy of mid-temperature natural gas based chemical looping reforming for hydrogen production

Steam methane reforming (SMR) needs the reaction heat at a temperature above 800 °C provided by the combustion of natural gas and suffers from adverse environmental impact and the hydrogen separated from other chemicals needs extra energy penalty. In order to avoid the expensive cost and high power consumption caused by capturing CO₂ after combustion in SMR, natural gas Chemical Looping Reforming (CLR) is proposed, where the chemical looping combustion of metal oxides replaced the direct combustion of NG to convert natural gas to hydrogen and carbon dioxide. Although CO₂ can be separated with less energy penalty when combustion, CLR still require higher temperature heat for the hydrogen production and cause the poor sintering of oxygen carriers (OC). Here, we report a high-rate hydrogen production and low-energy penalty of strategy by natural gas chemical-looping process with both metallic oxide reduction and metal oxidation coupled with steam. Fe₃O₄ is employed as an oxygen carrier. Different from the common chemical looping reforming, the double side reactions of both the reduction and oxidization enable to provide the hydrogen in the range of 500–600 °C under the atmospheric pressure. Furthermore, the CO₂ is absorbed and captured with reduction reaction simultaneously.Through the thermodynamic analysis and irreversibility analysis of hydrogen production by natural gas via chemical looping reforming at atmospheric pressure, we provide a possibility of hydrogen production from methane at moderate temperature. The reported results in this paper should be viewed as optimistic due to several idealized assumptions: Considering that the chemical looping reaction is carried out at the equilibrium temperature of 500 °C, and complete CO₂ capture can be achieved. It is assumed that the unreacted methane and hydrogen are completely separated by physical adsorption. This paper may have the potential of saving the natural gas consumption required to produce 1 m³ H₂ and reducing the cost of hydrogen production.     

Techno-economic feasibility of power to gas–oxy-fuel boiler hybrid system under uncertainty

One of the main challenges associated with utilisation of the renewable energy is the need for energy storage to handle its intermittent nature. Power-to-Gas (PtG) represents a promising option to foster the conversion of renewable electricity into energy carriers that may attend electrical, thermal, or mechanical needs on-demand. This work aimed to incorporate a stochastic approach (Artificial Neural Network combined with Monte Carlo simulations) into the thermodynamic and economic analysis of the PtG process hybridized with an oxy-fuel boiler (modelled in Aspen Plus^®). Such approach generated probability density curves for the key techno-economic performance indicators of the PtG process. Results showed that the mean utilisation of electricity from RES, accounting for the chemical energy in SNG and heat from methanators, reached 62.6%. Besides, the probability that the discounted cash flow is positive was estimated to be only 13.4%, under the set of conditions considered in the work. This work also showed that in order to make the mean net present value positive, subsidies of 68 €/MW_elh are required (with respect to the electricity consumed by PtG process from RES). This figure is similar to the financial aids received by other technologies in the current economic environment.     

Pd-decorated CNT as sensitive material for applications in hydrogen isotopes sensing - Application as gas sensor

Applicability of multiwall carbon nanotubes (MWCNTs) decorated with palladium nanoparticles as sensitive layer in a resistive microsensor for identification of hydrogen isotopes, Deuterium (²H) and Protium (¹H), has been demonstrated. Palladium nanoparticles were anchored on the MWCNTs surface via a chemical process involving micellization, from a precursor chloride solution, in high ultrasonic density field. Pd-MWCNTs are quasi-aligned between the interdigitated gold electrodes of a SiO₂ substrate by drop casting and di-electrophoretic alignment in Tetrahydrofuran (THF) and Nafion solution. The morphostructural characterization of the sensitive material has been carried out through SEM, TEM and Raman spectroscopy and its gas sensing properties were evaluated using electrical measurements performed on a series of isotope concentrations (ranging from 0.1% up to 1%, and from 1% to 4%, value to which hydrogen becomes explosive) diluted in argon, to observe the evolution of the sensor sensibility. The two hydrogen isotopes have different behaviors related to the adsorption on the Pd-MWCNT, which is well observed in the resistance change. Therefore, the sensor based on Pd-MWCNTs could be a viable solution to be integrated in systems for hydrogen leakage detection.     

Improving inter-plant integration of syngas production technologies by the recycling of CO2 and by-product of the Fischer-Tropsch process

This paper deals with the emission reduction in synthesis-gas production by better integration and increasing the energy efficiency of a high-temperature co-electrolysis unit combined with the Fischer-Tropsch process. The investigated process utilises the by-product of Fischer-Tropsch, as an energy source and carbon dioxide as a feedstock for synthesis gas production. The proposed approach is based on adjusting process streams temperatures with the further synthesis of a new heat exchangers network and optimisation of the utility system. The potential of secondary energy resources was determined using plus/minus principles and simulation of a high-temperature co-electrolysis unit. The proposed technique maximises the economic and environmental benefits of inter-unit integration. Two scenarios were considered for sharing the high-temperature co-electrolysis and the Fischer-Tropsch process. In the first scenario, by-products from the Fischer-Tropsch process were used as fuel for a high-temperature co-electrolysis. Optimisation of secondary energy sources and the synthesis of a new heat exchanger network reduce fuel consumption by 47% and electricity by 11%. An additional environmental benefit is reflected in emission reduction by 25,145 tCO₂/y. The second scenario uses fossil fuel as a primary energy source. The new exchanger network for the high-temperature co-electrolysis was built for different energy sources. The use of natural gas resulted in total annual costs of the heat exchanger network to 1,388,034 USD/y, which is 1%, 14%, 116% less than for coal, fuel oil and LPG, respectively. The use of natural gas as a fuel has the lowest carbon footprint of 7288 tCO₂/y. On the other hand, coal as an energy source has commensurable economic indicators that produce 2 times more CO₂, which can be used as a feedstock for a high-temperature co-electrolysis. This work shows how in-depth preliminary analysis can optimise the use of primary and secondary energy resources during inter-plant integration.     

Effect of hydrogen flow rate on the synthesis of carbon nanofiber using microwave-assisted chemical vapour deposition with ferrocene as a catalyst

Carbon nanostructure materials are becoming of considerable commercial importance, with interest growing rapidly over the decade since the discovery of carbon nanofibers. In this study, a new novel method is introduced to synthesize the carbon nanofibers by gas-phase, where a single-stage microwave-assisted chemical vapour deposition approach is used with ferrocene as a catalyst and acetylene and hydrogen as precursor gases. Hydrogen flow rate plays a significant role in the formation of carbon nanofibers, as being the carrier and reactant gas in the floating catalyst method. The effect of process parameters such as microwave power, radiation time and gas ratio of C₂H₂/H₂ was investigated statistically. The carbon nanofibers were characterized using scanning and transmission electron microscopy and thermogravimetric analysis. The analysis revealed that the optimized conditions for carbon nanofibers production were microwave power (1000 W), radiation time (35 min) and acetylene/hydrogen ratio (0.8). The field emission scanning electron microscope and transmission electron microscope analyses revealed that the vertical alignment of carbon nanofibers has tens of microns long with a uniform diameter ranging from 115 to 131 nm. High purity of 93% and a high yield of 12 g of CNFs were obtained. These outcomes indicate that identifying the optimal values for process parameters is important for synthesizing high quality and high CNF yield.     

TiO2 photocatalyst with single and dual noble metal co-catalysts for efficient water splitting and organic compound removal

Photocatalysts can be used both for air cleaning and solar energy harvesting through water splitting. However, pure TiO₂ photocatalysts are often inefficient and therefore co-catalysts are needed to improve the yield. To achieve this goal, we prepared TiO₂ and deposited Pt, Ir and Ru co-catalysts on its surface. Two base TiO₂ nanoparticles were used: P25 and rutile TiO₂ synthesized via hydrothermal method. Co-catalysts were deposited by wet impregnation technique using single element and a combination of two elements (Pt and Ir or Pt and Ru), followed by annealing in either air or H₂/Ar. Annealing in reducing atmosphere increased the photocatalytic activity of oxidation of isopropanol compared to annealing in air. We demonstrated a clear influence of the co-catalysts on the photocatalytic degradation of isopropanol and on electrochemical water-splitting reaction. The platinum-containing samples showed the best HER activity.     

Design and evaluation of hydrogen electricity reconversion pathways in national energy systems using spatially and temporally resolved energy system optimization

For this study, a spatially and temporally resolved optimization model was used to investigate and economically evaluate pathways for using surplus electricity to cover positive residual loads by means of different technologies to reconvert hydrogen into electricity. The associated technology pathways consist of electrolyzers, salt caverns, hydrogen pipelines, power cables, and various technologies for reconversion into electricity. The investigations were conducted based on an energy scenario for 2050 in which surplus electricity from northern Germany is available to cover the electricity grid load in the federal state of North Rhine-Westphalia (NRW).A key finding of the pathway analysis is that NRW's electricity demand can be covered entirely by renewable energy sources in this scenario, which involves CO₂ savings of 44.4 million tons of CO₂/a in comparison to the positive residual load being covered from a conventional power plant fleet. The pathway involving CCGT (combined cycle gas turbines) as hydrogen reconversion option was identified as being the most cost effective (total investment: € 43.1 billion, electricity generation costs of reconversion: € 176/MWh).Large-scale hydrogen storage and reconversion as well as the use of the hydrogen infrastructure built for this purpose can make a meaningful contribution to the expansion of the electricity grid. However, for reasons of efficiency, substituting the electricity grid expansion entirely with hydrogen reconversion systems does not make sense from an economic standpoint. Furthermore, the hydrogen reconversion pathways evaluated, including large-scale storage, significantly contribute to the security of the energy supply and to secured power generation capacities.     

Hydrogen production using chemical looping technology: A review with emphasis on H2 yield of various oxygen carriers

Natural H₂ in useful quantities is negligible, which makes hydrogen unsuitable as an energy resource compared to other fuels. H₂ production by solar, biological, or electrical sources needs more energy than obtained by combusting it. Lower generation of pollutants and better energy efficiency makes hydrogen a potential energy carrier. Hydrogen finds potential applications in automobile and energy production. However, the cost of producing hydrogen is extremely high. Chemical-looping technology for H₂ generation has caught widespread attention in recent years. This work, presents some recent findings and provides a comprehensive overview of different chemical looping techniques such as chemical looping reforming, syngas chemical looping, coal direct chemical looping, and chemical looping hydrogen generation method for H₂ generation. The above processes are discussed in terms of the relevant chemical reactions and the associated heat of reactions to ascertain the overall endothermicity or exothermicity of the H₂ production. We have compared the H₂ yield data of different Fe/Ni, spinel and perovskites-based oxygen carriers (OC) reported in previous literature. This review is the first comprehensive study to compare the H₂ yield data of all the previously reported oxygen carriers as a function of temperature and redox cycles. In addition, the article summarizes the characteristics and reaction mechanisms of various oxygen carrier materials used for H₂ generation. Lastly, we have reviewed the application of Density Function Theory (DFT) to study the effect of various dopant addition on the efficiency of H₂ production of the oxygen carriers and discussed ASPEN simulations of different chemical looping techniques.     

Co-generation of hydrogen and electricity from biodiesel process effluents

In this study, we apply a short-term voltage (0.2–0.8 V) to both crude glycerol (CG) and an anaerobic digestion (AD) effluent in a single-chamber microbial fuel cell (MFC) for power production. This improves the bioelectrogenesis in both CG (in MFC-1) and the AD effluent (in MFC-2), but higher power generation is attained in MFC-2. The use of domestic and synthetic wastewaters in the AD process leads to the generation of 195 and 350 mL H₂/L-medium, respectively. MFC-2 performs better than MFC-1 in terms of both voltage generation and chemical oxygen demand (COD) reduction. The application of 0.8 V yields a power density of 311 mW/m² (1.94 times higher than that of the control (160 mW/m²)). In addition, MFC-2 exhibits a 70% COD removal at 0.8 V, which decreases to 56% at 0.2 V. Thus, the application of a short-term voltage in MFC can stimulate both bioelectrogenesis and COD removal.     

Prospects and economic feasibility analysis of wind and solar photovoltaic hybrid systems for hydrogen production and storage: A case study of the Brazilian electric power sector

The work aims to verify the economic feasibility of renewable hybrid systems for hydrogen production and storage in the Brazilian electric power sector. The methodology applied is based on economic cost analyses of the two largest wind and solar photovoltaic plants in the country. As a result, the number of hours of electricity available for hydrogen production directly influences its cost. However, fully dedicated plants to produce green hydrogen have shown economically feasible to the exporter or other sectors, being trading hydrogen is more profitable than transforming it back into power. The model also concludes that wind and solar hybrid systems for hydrogen production and storage are still not economically viable in Brazil. The CAPEX of electrolysers and their operating losses are still very significant. Finally, hydrogen production and storage become economically feasible only from plants operating above 3000 h and for electrolysers with a CAPEX of USD 650/kWe.     

Performance evaluation of a solarized gas turbine system integrated to a high temperature electrolyzer for hydrogen production

In this paper, the performance of a solar gas turbine (SGT) system integrated to a high temperature electrolyzer (HTE) to generate hybrid electrical power and hydrogen fuel is analyzed. The idea behind this design is to mitigate the losses in the electrical power transmission and use the enthalpy of exhaust gases released from the gas turbine (GT) to make steam for the HTE. In this context, a GT system is coupled with a solar tower including heliostat solar field and central receiver to generate electrical power. To make steam for the HTE, a flameless boiler is integrated to the SGT system applying the SGT extremely high temperature exhaust gases as the oxidizer. The results indicate that by increasing the solar receiver outlet temperature from 800 K to 1300 K, the solar share increases from 22.1% to 42.38% and the overall fuel consumption of the plant reduces from 7 kg/s to 2.7 kg/s. Furthermore, flameless mode is achievable in the boiler while the turbine inlet temperature (TIT) is maintained at the temperatures higher than 1314 K. Using constant amounts of the SGT electrical power, the HTE voltage decreases by enhancing the HTE steam temperature which result in the augmentation of the overall hydrogen production. To increase the HTE steam temperature from 950 K to 1350 K, the rate of fuel consumption in the flameless boiler increases from 0.1 m/s to 0.8 m/s; however, since the HTE hydrogen production increases from 4.24 mol/s to 16 mol/s it can be interpreted that the higher steam temperatures would be affordable. The presented hybrid system in this paper can be employed to perform more thermochemical analyses to achieve insightful understanding of the hybrid electrical power-hydrogen production systems.     

Enhancing resistance of carbon deposition and reaction stability over nickel loaded fibrous silica-alumina (Ni/FSA) for dry reforming of methane

Syngas production from the dry reforming of methane is now the most extensively utilized method for removing massive amounts of greenhouse emissions. Effective solutions towards the utilization of greenhouse gases such as CO₂ and CH₄ are scarce, except for power generation in the energy sector, which is a major source of CO₂. Herein, dry reforming of methane was experimented for the first time using an effective catalytic system composed of 5% Ni fibrous silica-alumina (FSA) that was successfully fabricated using a hydrothermal method. The characterization results from XRD, FESEM mapping, TEM, BET,XRF, FTIR, H₂-TPR, TGA/DTA, and Raman spectra demonstrated that Ni/FSA is composed of orderly Ni dispersion, small particles of Ni, robust basic sites, and high oxygen vacancies which enhanced the catalytic efficiency. The synthesized Ni/FSA also reduced coke formation and had long-term stability with no evidence of inactivation during and after the catalytic cycles. The superior activity of Ni/FSA was manifested in the high conversion rates of CH₄ and CO₂ at 97% and 92% respectively, with a H₂:CO ratio of ≈ 1. The stability of Ni/FSA was also sustained over 30 h of operation at 800 °C. The findings of the Raman, TEM, and TGA/DTA tests revealed that the spent Ni/FSA catalysts did not exhibit graphitic carbon or metal sintering in significant amounts when compared to commercial Ni–Si/Al catalysts.     

Wind-powered 250 kW electrolyzer for dynamic hydrogen production: A pilot study

Alkaline water electrolysis is the most promising approach for the industrial production of green hydrogen. This study investigates the dynamic operational characteristics of an industrial-scale alkaline electrolyzer with a rated hydrogen production of 50 m³/h. Strategies for system control and equipment improvement in dynamic-mode alkaline electrolytic hydrogen production are discussed. The electrolyzer can operate over a 30%–100% rated power load, thereby facilitating high-purity (>99.5%) H₂ production, competitive DC energy efficiency (4.01–4.51 kW h/Nm³ H₂, i.e., 73.1%–65.0% LHV), and good gas–liquid fluid balance. A safe H₂ content of 2% in O₂ (50% LFL) can be guaranteed by adjusting the system pressure. In transient operation, the electrolyzer can realize minute-level power and pressure modulation with high accuracy. The results confirm that the proposed alkaline electrolyzer can absorb highly fluctuating energy output from renewables because of its capability to operate in a dynamic mode.     

Reducing the fuel consumption and emissions with the use of an external fuel cell hybrid power unit for electric taxiing at airports

Airport ground operations have a great impact on the environment. Various innovative solutions have been proposed for aircraft to perform taxi movements by deactivating their main engines. Although these solutions are environmentally beneficial, onboard and external electric taxiing solutions that are actively used and planned to be used in airports are not completely carbon-free. The disadvantages of the existing solutions can be alleviated by using an external fuel cell hybrid power unit to meet the energy required for taxiing that does not put additional weight on the aircraft. To reveal the power and energy required by the system, Airbus A320-200, which is a narrow-body aircraft and frequently used in airports, has been considered in this study. To determine the physical requirements of the aircraft for taxiing, a total of 900 s taxi-out movement consisting of four different periods with different runway slope, headwind, and maximum speeds were examined. According to the determined physical requirements, the conceptual design of the proposed fuel cell battery system was created and the physical data of the system for each period were obtained using the Matlab Simulink environment. As a result of the simulation, it is seen that the system consumes approximately 1.96 g of hydrogen per second. In addition, it has been calculated that 578.34 kg of CO₂ is emitted during the taxi-out movement. The results also show that as a result of using the proposed system, approximately 14.6 million tons of CO₂ emission per year can be prevented.