Liquid hydrogen production via hydrogen sulfide methane reformation

Hydrogen sulfide (H₂S) methane (CH₄) reformation (H₂SMR) (2H₂S + CH₄ = CS₂ + 4H₂) is a potentially viable process for the removal of H₂S from sour natural gas resources or other methane containing gases. Unlike steam methane reformation that generates carbon dioxide as a by-product, H₂SMR produces carbon disulfide (CS₂), a liquid under ambient temperature and pressure—a commodity chemical that is also a feedstock for the synthesis of sulfuric acid. Pinch point analyses for H₂SMR were conducted to determine the reaction conditions necessary for no carbon lay down to occur. Calculations showed that to prevent solid carbon formation, low inlet CH₄ to H₂S ratios are needed. In this paper, we analyze H₂SMR with either a cryogenic process or a membrane separation operation for production of either liquid or gaseous hydrogen. Of the three H₂SMR hydrogen production flowsheets analyzed, direct liquid hydrogen generation has higher first and second law efficiencies of exceeding 80% and 50%, respectively.     

Assessment of offshore liquid hydrogen production from wind power for ship refueling

Green hydrogen from electrolysis has become the most attractive energy carrier for making the transition from fossil fuels to carbon-free energy sources possible. Especially in the naval sector, hydrogen has the potential to address environmental targets due to the lack of low-carbon fuel options. This study aims at investigating an offshore liquefied green hydrogen production plant for ship refueling. The plant comprises a wind farm for renewable electricity generation, an electrolyzer stack for hydrogen production, a water treatment unit for demineralized water production, and a hydrogen liquefaction plant for hydrogen storage and distribution to ships. A pre-feasibility study is addressed to find the optimal capacities of the plant that minimize the payback time. The model results show that the electrolyzer capacity shall be set equal to a value between 80% and 90% of the wind farm capacity to achieve the minimum payback times. Additionally, the wind farm capacity shall be higher than about 150 MW to limit the payback time to values lower than 11 years for a fixed hydrogen price of 6 €/kg. The Levelized Cost of Hydrogen results to be below 4 €/kg for a wide range of plant capacities for a lifetime of the plant of 25 years. Thus, the model shows that this plant is economically feasible and can be reproduced similarly for different locations by rescaling the different selected technologies. In this way, the naval sector can be decarbonized thanks to a new infrastructure for the production and refueling of liquified green hydrogen directly provided on the sea.     

Development of large-scale hydrogen liquefaction processes from 1898 to 2009

This paper presents a review of the development of large-scale hydrogen liquefaction processes throughout the world from 1898 to 2009. First, there is a concise literature review including numerous past, present, and future designs given such as the first hydrogen liquefaction device, long time ago simple theoretical processes, today's actual plants with efficiencies 20–30%, a list of the capacity and location of every hydrogen liquefaction plant in the world, and some modern more efficient proposed conceptual plants with efficiencies 40–50%. After that, further information about the development and improvement potential of future large-scale liquid hydrogen liquefaction plants is given. It is found that every current plant is based on the pre-cooled Claude system, which is still the same as was 50 years ago with little improvement. Methods to resolve the challenges of the future plants include proposing completely new configurations and efficient systems coupled with improved efficiencies of the main system components such as compressors, expanders, and heat exchangers. Finally, a summary and comparison of the process efficiencies are described, including a newly proposed Multi-component Refrigerant (MR) system being developed by NTNU and SINTEF Energy Research AS.     

Technoeconomics of large-scale clean hydrogen production – A review

Hydrogen is widely used in many industries, yet its role in the clean energy transition goes beyond being an element of these industries. Near-term practical large-scale clean hydrogen production can be made available by involving nuclear, solar, and other renewable energy sources in the process of hydrogen production, and coupling their energy systems to sustainable carbon-free hydrogen technologies. This requires further investigation and assessment of the different alternatives to achieve clean hydrogen using these pathways. This paper assesses the technoeconomics of promising hydrogen technologies that can be coupled to nuclear and solar energy systems for large-scale hydrogen production. It also provides an overview of the design, status and advances of these technologies.     

Simulation on a proposed large-scale liquid hydrogen plant using a multi-component refrigerant refrigeration system

A proposed liquid hydrogen plant using a multi-component refrigerant (MR) refrigeration system is explained in this paper. A cycle that is capable of producing 100 tons of liquid hydrogen per day is simulated. The MR system can be used to cool feed normal hydrogen gas from 25 °C to the equilibrium temperature of −193 °C with a high efficiency. In addition, for the transition from the equilibrium temperature of the hydrogen gas from −193 °C to −253 °C, the new proposed four H₂ Joule–Brayton cascade refrigeration system is recommended. The overall power consumption of the proposed plant is 5.35 kWh/kg_LH2, with an ideal minimum of 2.89 kWh/kg_LH2. The current plant in Ingolstadt is used as a reference, which has an energy consumption of 13.58 kWh/kg_LH2 and an efficiency of 21.28%: the efficiency of the proposed system is 54.02% or more, where this depends on the assumed efficiency values for the compressors and expanders. Moreover, the proposed system has some smaller-size heat exchangers, much smaller compressor motors, and smaller crankcase compressors. Thus, it could represent a plant with the lowest construction cost with respect to the amount of liquid hydrogen produced in comparison to today’s plants, e.g., in Ingolstadt and Leuna. Therefore, the proposed system has many improvements that serve as an example for future hydrogen liquefaction plants.     

The future of hydrogen – opportunities and challenges

The following article is reproduced from ‘The Hydrogen Economy: Opportunities and Challenges’, edited by Michael Ball and Martin Wietschel, to be published by Cambridge University Press in June 2009. In the light of ever-increasing global energy use, the increasing cost of energy services, concerns over energy supply security, climate change and local air pollution, this book centres around the question of how growing energy demand for transport can be met in the long term. Given the sustained interest in and controversial discussion of the prospects of hydrogen, the authors highlight the opportunities and the challenges of introducing hydrogen as alternative fuel in the transport sector from an economic, technical and environmental point of view. Through its multi-disciplinary approach the book provides a broad range of researchers, decision makers and policy makers with a solid and wide-ranging knowledge base concerning the hydrogen economy.     

High-temperature electrolysis for large-scale hydrogen and syngas production from nuclear energy – summary of system simulation and economic analyses

A research and development program is under way at the Idaho National Laboratory (INL) to assess the technological and scale-up issues associated with the implementation of solid-oxide electrolysis cell technology for efficient high-temperature hydrogen production from steam. This work is supported by the US Department of Energy, Office of Nuclear Energy, under the Nuclear Hydrogen Initiative. This paper will provide an overview of large-scale system modeling results and economic analyses that have been completed to date. System analysis results have been obtained using the commercial code UniSim, augmented with a custom high-temperature electrolyzer module. Economic analysis results were based on the DOE H2A analysis methodology. The process flow diagrams for the system simulations include an advanced nuclear reactor as a source of high-temperature process heat, a power cycle and a coupled steam electrolysis loop. Several reactor types and power cycles have been considered, over a range of reactor outlet temperatures. Pure steam electrolysis for hydrogen production as well as coelectrolysis for syngas production from steam/carbon dioxide mixtures have both been considered. In addition, the feasibility of coupling the high-temperature electrolysis process to biomass and coal-based synthetic fuels production has been considered. These simulations demonstrate that the addition of supplementary nuclear hydrogen to synthetic fuels production from any carbon source minimizes emissions of carbon dioxide during the production process.     

Comparative techno-economic assessment of a large-scale hydrogen transport via liquid transport media

A large-scale point to point hydrogen transport is one strategy for a prospective energy import scenario for certain countries. The case for a hydrogen transport from Australia to Japan has been addressed in several studies. However, most studies lack transparency and detailed insights into the made assumptions thus a fair evaluation of different transport pathways is challenging. To address this issue, we developed a model where a large-scale point to point hydrogen transport of liquid hydrogen is compared with the transport via liquid organic hydrogen carrier (LOHC), namely via methyl cyclohexane and hydrogenated dibenzyl toluene. We analyzed, where energy is required along the different pathways, where hydrogen losses do occur and how the costs are put together. Furthermore, the influence of hydrogen feed costs is also considered. For hydrogen production costs of 5 €₂₀₁₈/kg_H2 the total delivery costs are in the range of 6.40– 8.10 €₂₀₁₈/kg_H2.     

Green hydrogen production potential for developing a hydrogen economy in Pakistan

Pakistan's energy crisis can be diminished through the use of Renewable and alternative sources of energy. Hydrogen as an energy vector is likely to replace the fossil fuels in the future owing to the political, financial and environmental factors associated with the latter. In this regard it is imperative that conscious effort is directed towards the production of hydrogen from Renewable resources. Renewable energy resources are abundantly available in Pakistan. The need to produce Hydrogen from Renewable resources in Pakistan (or any developing economy) is investigated because it is possible to store vast amount of intermittent renewable energy for later use. Thus the introduction of Hydrogen in the energy supply chain implies the start of a Pakistan Hydrogen Economy. Many nations have developed the Hydrogen Energy Roadmap, and if Pakistan has to follow suite it is only possible through the employment of Renewable energy resources. This study estimates the potential of different Renewable resources available in Pakistan i.e. Solar, Wind, Geothermal, Biomass and Municipal Solid waste. An estimate is then made for the potential of producing hydrogen from various established technologies from each of these Renewable resources. A number of reviews have been published stating the availability and usage of Renewable energy in Pakistan; however no specific study has been focused on the use of Renewable resources for developing a Hydrogen economy or a power-to-gas system in Pakistan. This study concludes that that Biomass is the most feasible feedstock for developing a Hydrogen supply chain in Pakistan with a potential to generate 6.6 million tons of Hydrogen annually, followed by Solar PV that has a generation potential of 2.8 million tons and then Municipal solid waste with a capacity of 1 million ton per annum.     

Comparison criteria for large-scale hydrogen liquefaction processes

In a hydrogen liquefier the pre-compression of feed gas has generally higher stand-alone exergy efficiency than the cooling and liquefaction sub-process. Direct comparison of liquefiers based on overall exergy efficiency and specific power consumption will favour those with a higher portion of pre-compression. A methodology for comparing hydrogen liquefaction processes that compensates for non-uniformity in feed specifications has been developed and applied to three different hydrogen liquefiers. The processes in consideration have been modified to have equal hydrogen feed pressure, resulting in a more consistent comparison. Decreased feed pressure results in generally higher power consumption but also higher exergy efficiency, and vice versa. This approach can be adapted to the boundary conditions that the liquefaction process will be subject to in a real energy system.     

Feasibility of an energy conversion system in Canada involving large-scale integrated hydrogen production using solid fuels

A large-scale hydrogen production system is proposed using solid fuels and designed to increase the sustainability of alternative energy forms in Canada, and the technical and economic aspects of the system within the Canadian energy market are examined. The work investigates the feasibility and constraints in implementing such a system within the energy infrastructure of Canada. The proposed multi-conversion and single-function system produces hydrogen in large quantities using energy from solid fuels such as coal, tar sands, biomass, municipal solid waste (MSW) and agricultural/forest/industrial residue. The proposed system involves significant technology integration, with various energy conversion processes (such as gasification, chemical looping combustion, anaerobic digestion, combustion power cycles-electrolysis and solar–thermal converters) interconnected to increase the utilization of solid fuels as much as feasible within cost, environmental and other constraints. The analysis involves quantitative and qualitative assessments based on (i) energy resources availability and demand for hydrogen, (ii) commercial viability of primary energy conversion technologies, (iii) academia, industry and government participation, (iv) sustainability and (v) economics. An illustrative example provides an initial road map for implementing such a system.     

Opportunities and data requirements for data-driven prognostics and health management in liquid hydrogen storage systems

During the past decade, Prognostics and Health Management (PHM) has become an important set of tools in various areas of industry and academic reliability engineering. PHM consists of a variety of mathematical and computational methods used to support data-driven decision-making to increase the safety, availability, and reliability of complex engineering systems. In particular, PHM can provide crucial insight into reliability and safety design improvements for developing technologies where historical performance and failure data are limited. This is the case of hydrogen fueling and storage technologies. This work presents a high-level approach for designing data-driven PHM applications for bulk liquid hydrogen (LH₂) storage systems for hydrogen fueling stations. This paper addresses core aspects of the design, development, and implementation of data-driven PHM applications that can improve the reliability assessment of hydrogen components. The analysis focuses on the relationship between data availability and diagnostic/prognostic capabilities; potential challenges; and integration schemes for current risk mitigation measures. We identify potential condition-monitoring data sources for key components in an LH₂ storage system, including storage tanks, piping, and pumps. We determine that the short-term goals for the implementation of data-driven models in PHM frameworks in hydrogen systems should focus on developing adequate data collection and analysis strategies, as well as exploring the effect on reliability, safety, and regulations for hydrogen systems.     

Analysis of copper chlorine electrolysis for large-scale hydrogen production

Nuclear hydrogen production is experiencing an unprecedented momentum worldwide, in response to the increasing demand for clean large-scale hydrogen production in line with the outcomes of the UN Conference of the Parties (COP26). A seamless integration of several innovative nuclear designs including Small Modular Reactors with steam Rankine cycle and the cogeneration of Hydrogen using thermochemical water-splitting cycles (e.g., the Cu–Cl cycle) is possible for a complete solution of hydrogen, oxygen, and electric power generation. In this paper, a process and flow sheet for large-scale hydrogen production by CuCl electrolysis at 50 tonnes per day is proposed and analyzed. The scaled-up process and flow sheet is based on lab-scale experience with 50 l/h hydrogen generation. Pressurized Cu–Cl electrolysis and basic electrolysis are reported to support the scaling up parameters, assumptions, and considerations. Based on determined sizing parameters and energy analysis, the Cu–Cl cycle consumes substantially less primary energy (thermal) than water electrolysis, which makes it a serious competitor, despite its obvious higher investment cost in the hardware.     

Comparative analysis of associated cost of nuclear hydrogen production using IAEA hydrogen cost estimation program

The interest in non-electric applications of nuclear energy is rising ranging from hydrogen production, district heating, seawater desalination, and various industrial applications to provide long-term answers for a variety of energy issues that both present and future generations will confront. Hydrogen is a dynamic fuel that can be used across all industrial sectors to lower carbon intensity. This study, therefore, aims at estimating the cost of nuclear hydrogen production from some light water reactors using International Atomic Energy Agency (IAEA) Hydrogen Calculator (HydCalc) program and comparing the result with similar existing studies conducted by other scholars using the Hydrogen Economic Evaluation Program (HEEP) program. The study employs six existing Light Water Reactors (LWRs) comprised of Korea Advanced Power Reactor 1400 MW electricity (APR1400), Russian VVER-1200, Davis-Besse Nuclear Power Plant in Ohio, Prairie Island NPP in Minnesota, Nine Mile Point NPP in New York, and Arizona Public Service's Palo Verde NPP to evaluate the Levelized cost of nuclear hydrogen production. Estimation of hydrogen demand was performed without carbon dioxide (CO₂) tax since nuclear power has zero CO₂ emission. The Levelized costs obtained using IAEA HydCalc and HEEP Programme were compared as follows; APR1400 cost are 2.6$/kg and 3.18$/kg, VVER1200 cost are 3.8$/kg and 3.44$/kg; Exelon cost are 1.7$/kg and 4.85$/kg; Davis Besse cost are 3.9$/kg and 3.09$/kg; Parlo Verde cost are 3.5$/kg and 4.77$/kg; Xcel Energy cost are 3.63$/kg and 0.69$/kg. The cost of hydrogen production using HEEP for Xcel Energy's Prairie Island NPP is 0.69 $/kg. This is because the reactor utilizes High Temperature Steam Electrolysis, method of hydrogen production, while the other methods employs Low Temperature Electrolysis. The results shows that the final price of the hydrogen for each reactor technology depends not only on the production method but also on the cost of the nuclear power plant and the production rate of the hydrogen plant.     

Safety analysis of leakage in a nuclear hydrogen production system

Due to its unique advantages, such as clean and pollution-free, hydrogen energy has gradually improved its energy transition position. Constructing nuclear hydrogen production systems is a necessary means to achieve large-scale hydrogen production, and the study of hydrogen leakage and diffusion behavior is critical to commercializing hydrogen production systems. In engineering practice, the distance between the hydrogen storage device and the nuclear power plant is an important indicator to measure the safety of nuclear hydrogen production. To study the influence of gas storage tank's own conditions and external environmental conditions on leakage diffusion, influencing factors such as wind speed, leakage direction, leakage diameter, leakage height, and leakage angle are discussed in the present study. By calculating severe working conditions combined with the above multiple factors, the longest distance of hydrogen diffusion is determined. Finally, peak overpressure impact generated by hydrogen explosion was evaluated, and the minimum separation distance required to avoid safety risks was predicted. The results demonstrate that when the wind direction is consistent with the leakage direction, and the leakage angle is 0°, the higher the wind speed, the larger the leakage diameter and the lower the leakage height, resulting in a longer diffusion distance. Under more extreme and severe working conditions, the diffusion distance of combustible hydrogen cloud can reach as far as 237 m. Once hydrogen diffusion explodes, the minimum separation distance required is about 338 m. This research provides an effective method for safety risk assessment of a nuclear hydrogen production system.     

The status of conventional world oil reserves—Hype or cause for concern?

The status of world oil reserves is a contentious issue, polarised between advocates of peak oil who believe production will soon decline, and major oil companies that say there is enough oil to last for decades.     

Adapting the French nuclear fleet to integrate variable renewable energies via the production of hydrogen: Towards massive production of low carbon hydrogen?

Producing low-carbon hydrogen at a competitive rate is becoming a new challenge with respect to efforts to reduce greenhouse gas emissions. We examine this issue in the French context, which is characterised by a high nuclear share and the target to increase variable renewables by 2050. The goal is to evaluate the extent to which excess nuclear power could contribute to producing low-carbon hydrogen.Our approach involves designing scenarios for nuclear and renewables, modelling and evaluating the potential nuclear hydrogen production volumes and costs, examining the latter through the scope of hydrogen market attractiveness and evaluating the potential of CO₂ mitigation.This article shows that as renewable shares increase, along with the hydrogen market expected growth driven by mobility uses, opportunities are created for the nuclear operator. If nuclear capacities are maintained, nuclear hydrogen production could correspond to the demand by 2030. If not, possibilities could still exist by 2050.     

Technical assessment of cryo-compressed hydrogen storage tank systems for automotive applications

On-board and off-board performance and cost of cryo-compressed hydrogen storage are assessed and compared to the targets for automotive applications. The on-board performance of the system and high-volume manufacturing cost were determined for liquid hydrogen refueling with a single-flow nozzle and a pump that delivers liquid H₂ to the insulated cryogenic tank capable of being pressurized to 272 atm. The off-board performance and cost of delivering liquid hydrogen were determined for two scenarios in which hydrogen is produced by central steam methane reforming (SMR) or by central electrolysis. The main conclusions are that the cryo-compressed storage system has the potential of meeting the ultimate target for system gravimetric capacity, mid-term target for system volumetric capacity, and the target for hydrogen loss during dormancy under certain conditions of minimum daily driving. However, the high-volume manufacturing cost and the fuel cost for the SMR hydrogen production scenario are, respectively, 2–4 and 1.6–2.4 times the current targets, and the well-to-tank efficiency is well short of the 60% target specified for off-board regenerable materials.     

On-board and Off-board performance of hydrogen storage options for light-duty vehicles

Leading physical and materials-based hydrogen storage options are evaluated for their potential to meet the vehicular targets for gravimetric and volumetric capacity, cost, efficiency, durability and operability, fuel purity, and environmental health and safety. Our analyses show that hydrogen stored as a compressed gas at 350–700 bar in Type III or Type IV tanks cannot meet the near-term volumetric target of 28 g/L. The problems of dormancy and hydrogen loss with conventional liquid H₂ storage can be mitigated by deploying pressure-bearing insulated tanks. Alane (AlH₃) is an attractive hydrogen carrier if it can be prepared and used as a slurry with >50% solids loading and an appropriate volume-exchange tank is developed. Regenerating AlH₃ is a major problem, however, since it is metastable and it cannot be directly formed by reacting the spent Al with H₂. We have evaluated two sorption-based hydrogen storage systems, one using AX-21, a high surface-area superactivated carbon, and the other using MOF-177, a metal-organic framework material. Releasing hydrogen by hydrolysis of sodium borohydride presents difficult chemical, thermal and water management issues, and regenerating NaBH₄ by converting B–O bonds is energy intensive. We have evaluated the option of using organic liquid carriers, such as n-ethylcarbazole, which can be dehydrogenated thermolytically on-board a vehicle and rehydrogenated efficiently in a central plant by established methods and processes. While ammonia borane has a high hydrogen content, a solvent that keeps it in a liquid state needs to be found, and developing an AB regeneration scheme that is practical, economical and efficient remains a major challenge.