On-site hydrogen production from transportation fuels: An overview and techno-economic assessment

Hydrogen production for future transportation applications have received increased interest due to its inherent environmental and efficiency benefits. Currently, hydrogen is produced from natural gas and naphtha for its use in refineries for clean fuel production along with its use in ammonia production. The hydrogen demand will grow in future for hydrogen based fuel cell vehicles. Significant research is underway to produce hydrogen from renewable and fossil fuel sources. However, on-site hydrogen production using existing fuel and gas station infrastructure to support future hydrogen based fuel cell vehicles has advantages over other approaches. In this context, this study is focused on a techno-economic assessment of hydrogen production from transportation fuels using different conversion technologies. In addition, detailed economics with higher capacity and volume of the hydrogen stations are also discussed. Finally, a detailed roadmap is presented to produce on-site hydrogen at commercial scale.     

A molecular dynamics simulation study on solubility behaviors of polycyclic aromatic hydrocarbons in supercritical water/hydrogen environment

Violates containing polycyclic aromatic hydrocarbons (PAHs) were precipitated in the process of fast pyrolysis and gasification of coal and organic substances. PAHs are one of bottlenecks of entire coal gasification for hydrogen production. In current work, the solubility of PAH oil droplets in supercritical water/hydrogen circumstances were investigated based on molecular dynamics simulation, which was beneficial for understanding the solubility behaviors of PAHs in supercritical water/hydrogen environment. The results showed that heavy PAHs were rather stable in the water phase. Supercritical water along with hydrogen promoted the miscibility of PAHs compared with that of pure supercritical water. Furthermore, high density and high temperature facilitated the rapid solvation of PAHs in supercritical water/hydrogen environment. This paper is expected to provide a theoretical support for the development of complete coal gasification technology for hydrogen production.     

Application of atmospheric pressure microwave plasma source for hydrogen production from ethanol

In contrast to conventional technologies of hydrogen production like water electrolysis or coal gasification we propose a method based on the atmospheric pressure microwave plasma. In this paper we present results of the experimental investigations of the hydrogen production from ethanol in the atmospheric pressure plasma generated in waveguide-supplied cylindrical type nozzleless microwave (915 MHz and 2.45 GHz) plasma source (MPS). Argon, nitrogen and carbon dioxide were used as a working gas. All experimental tests were performed with the working gas flow rate Q ranged from 1500 to 3900 NL/h and absorbed microwave power P_A up to 6 kW. Ethanol was introduced into the plasma as vapours carried with the working gas. The process resulted in the ethanol conversion rate greater than 99%. The hydrogen production rate was up to 210 NL[H₂]/h and the energy efficiency was 77 NL[H₂] per kWh of absorbed microwave energy.     

High-temperature reactor for hydrogen production by partial oxidation of hydrocarbons

Today, conversion of hydrocarbons is one of the most common hydrogen production technologies. This paper presents a design of a high-temperature reactor — the main component of a hydrogen production unit using partial oxidation of hydrocarbons — as well as a physical model of gas generation. It also presents a schematic diagram of an experimental setup as well as results of experimental studies on steady-state modes of partial oxidation in the combustion chamber of a high-temperature reactor for various hydrocarbon feed/oxidant combinations. In the course of the study, we identified patterns that describe how the excess oxidant ratio affects the composition of products of incomplete combustion of hydrocarbons to obtain hydrogen-containing gas of the required composition and parameters for hydrogen production. We propose a method to calculate nominal geometric dimensions of a high-temperature reactor, which makes it possible to estimate its weight and size at the design stage. The paper presents results of experimental studies confirming the adequacy of the proposed method.     

Carbon black and hydrogen production process analysis

The adoption of new environmentally responsible technologies, as well as, energy efficiency improvements in equipment and processes help to reduce CO2 rate emission into the atmosphere, contributing in delaying the consequences of intensive use of fossil fuels. For more effective actions, it is necessary to make the transition from the fossil-based to the renewable source economy. In this context, hydrogen fuel has a special role as clean vector of energy. Hydrogen has the potential to be decisive in mitigating greenhouse gas emissions, but fossil fuels high profitability due to global energy dependency actually drives the global economy.While renewable energy sources are not worldwide fully established, new technologies should be developed and used for the recovery of energetic streams nowadays wasted, to decarbonize hydrocarbons and to improve systems efficiency creating a path that can help nations and industries in the needed energy economy transition. Hydrogen gas can be generated by various methods from different sources such as coal and water. Currently, almost all of the hydrogen production is for industrial purpose and comes from the Steam Reforming, while the use of hydrogen in fuel cells is only incipient.The article analysis the plasma pyrolysis of hydrocarbons as a decarbonization option to contribute as a step towards hydrogen economy. It presents the Carbon Black and Hydrogen Process (CB&H Process) as an alternative option for hydrogen generation at large scale facility, suitable for supplying large amounts of high-purity carbon in elemental form. CB&H Process refers to a plant with hydrogen thermal plasma reactor able to decompose Hydrocarbons (HC's) into Hydrogen (H2) and Carbon Black (CB), a cleaner technology than its competing processes, capable of generating two products with high added value. Considering the Brazilian context in which more than 80% of the generated electricity comes from renewable sources, the use of electricity as one of the inputs in the process does not compromise the objective of reducing greenhouse gas emissions. It is important to consider that the use of renewable energy to produce two products derived from fossil fuels in a clean way represents integration of technologies into a more efficient system and an arrangement that contributes to the transition from fossil fuels to renewables.The economic viability of the CB&H process as a hydrogen generation unit (centralized) for refining applications also depends on the cost of hydrogen production by competing processes. Steam Methane Reforming (SMR) is a widespread method that produces twice the amount of hydrogen generated by natural gas plasma pyrolysis, but it emits CO2 gas and consumes water, while CB&H process produces solid carbon. For this reason, the paper seeks the carbon production cost by plasma pyrolysis as a breakeven point for large-scale hydrogen generation without water consumption and carbon dioxide emissions.     

Optimization experimental design of stable production life and estimated ultimate recovery in gaseous compound of hydrogen and carbon from shale reservoir

In this study, a mixed numerical model is established to simulate the production performance of gaseous compound of hydrogen and carbon in shale reservoir. Estimated ultimate recovery (EUR) and stable production life (SPL) of gaseous compound of hydrogen and carbon are affected by reservoir parameters and production control parameters, such as Langmuir pressure, Langmuir volume, critical desorption pressure, fracture half length, permeability in stimulated reservoir volume (SRV) area, bottom hole flow pressure and production of gaseous compound of hydrogen and carbon. Therefore, in the later research, in order to reduce the number of numerical experiments, the orthogonal experimental method is used to optimize the influence of hydrocarbon ERU and SPL, and analyze the main control factors affecting these two indices at the same time. The purpose of this paper is to optimize the production of hydrocarbons by orthogonal experimental method and find the main controlling factors affecting the production of compound of hydrogen and carbon. Two groups of orthogonal experiments were designed to find the best scheme in the process of compound of hydrogen and carbon development. The calculative results show that the output of hydrogen and carbon compounds has a highly significant impact on SPL, Langmuir volume and capability in SRV have a significant impact, and Langmuir pressure Critical destruction pressure and hydraulic fracture half-length had no significant effects.     

Thermo-fluid dynamics modelling of steam electrolysis in fully-assembled tubular high-temperature proton-conducting cells

Electrolysis based on renewable energies offers a promising carbon-free solution for hydrogen generation and storage. The recent developments of proton ceramic electrolysis cells operating at intermediate temperatures bear promise of superior energy efficiency compared to oxide ion conducting electrolytes. Here, a proton ceramic Single Engineering Unit (SEU) design is optimized for steam electrolysis using a computational fluid dynamics (CFD) model implemented in a COMSOL Multiphysics software. The SEU is an all-in-one tubular cell arrangement that constitutes the smallest electrolysis unit and enables efficient, adaptable pressurized hydrogen generation. The parametrical modelling study is conducted for two adiabatic operation scenarios with distinct steam conversion rates and tested for multiple key parameters, namely internal and external chamber pressures and inlet stream temperature. The modelling results show that low steam conversions enable operation at higher current densities and that the thermoneutral voltage for a fixed steam conversion is highly sensitive to the process conditions and operation modes. The increment of the pressure of the generated hydrogen implies a reduced production rate at thermoneutral voltage, although it can be compensated with an enhanced steam pressure or a reduced inlet temperature. Additionally, the introduction of a porous medium as the SEU current collector in the steam chamber enhances heat transport within this chamber. The area specific resistance of the system determines the current density, enforcing an adaption of the area of the electrolyser to satisfy the target hydrogen production and energy efficiency. The resulting proposed SEU design and adapted operational parameters allow effective delivery of pressurized dry hydrogen for a wide range of conditions and applications.     

Kinetic Monte Carlo simulation of hydrogen production from photocatalytic water splitting in the presence of methanol by 1 wt% Au/TiO2

In this research, using the kinetic Monte Carlo simulation (KMC), the hydrogen production from a water-methanol mixture using Au/TiO₂ photocatalyst is investigated. A mechanism is proposed, and the rate constants of the reaction steps are specified. The reaction rate constants of different steps and the concentration of the active sites on the photocatalyst surface were determined. An excellent match between simulated and experimental data confirms the results. The electron-hole pair production, methanol adsorption on the photocatalyst surface, and electron-hole recombination steps are considered the most critical steps. To study the effects of independent variables (initial concentration of methanol, photocatalyst dosage, pH, and time of reaction) on the produced hydrogen, a combination of KMC simulation and design of experiment was employed. The concentration of photocatalysis has the highest and pH has the lowest effect on the hydrogen production. The optimal conditions for photocatalytic hydrogen production are presented.     

Hydrogen from electrochemical reforming of C1–C3 alcohols using proton conducting membranes

This study investigates the production of hydrogen from the electrochemical reforming of short-chain alcohols (methanol, ethanol, iso-propanol) and their mixtures. High surface gas diffusion Pt/C electrodes were interfaced to a Nafion polymeric membrane. The assembly separated the two chambers of an electrochemical reactor, which were filled with anolyte (alcohol + H₂O or alcohol + H₂SO₄) and catholyte (H₂SO₄) aqueous solutions. The half-reactions, which take place upon polarization, are the alcohol electrooxidation and the hydrogen evolution reaction at the anode and cathode, respectively. A standard Ag/AgCl reference electrode was introduced for monitoring the individual anodic and cathodic overpotentials. Our results show that roughly 75% of the total potential losses are due to sluggish kinetics of the alcohol electrooxidation reaction. Anodic overpotential becomes larger as the number of C-atoms in the alcohol increases, while a slight dependence on the pH was observed upon changing the acidity of the anolyte solution. In the case of alcohol mixtures, it is the largest alcohol that dictates the overall cell performance.     

Sustainability and challenges in hydrogen production: An advanced bibliometric analysis

Hydrogen has a high and diversified amount of feedstocks, methods, and improvement processes for its production. In recent years, studies on hydrogen production have been growing and diversifying to a greater extent. Hydrogen production can be based on renewable feedstocks such as biomass or fossil fuels such as petroleum. An analysis of 10,655 publications from the Web of Science Core Collection database (2010–2022) was performed using VOSviewer, CiteSpace and Microsoft excel. The top three organizations that had the highest number of publications in the field of hydrogen production included the Chinese Academy Of Sciences, Ontario Tech University and Xi An Jiaotong University. The journal with the largest number of publications is the International Journal Of Hydrogen Energy. In addition to organizations and journals, the most promising authors and literature in this field of research were analyzed. Through cluster analysis, it was found that two constant search fields were Photocatalytic hydrogen production and Fermentative hydrogen production. Future studies should focus on process design, continuous photo-hydrogen production and looping steam. This bibliometric study focused on illustrating the overview of hydrogen production research, conducting a systematic survey of current research, which could be used by industry professionals and researchers interested in this area.     

Estimation of hydrogen production in genetically modified E. coli fermentations using an artificial neural network

Biological hydrogen production is an active research area due to the importance of this gas as an energy carrier and the advantages of using biological systems to produce it. A cheap and practical on-line hydrogen determination is desired in those processes. In this study, an artificial neural network (ANN) was developed to estimate the hydrogen production in fermentative processes. A back propagation neural network (BPNN) of one hidden layer with 12 nodes was selected. The BPNN training was done using the conjugated gradient algorithm and on-line measurements of dissolved CO₂, pH and oxidation-reduction potential during the fermentations of cheese whey by Escherichia coli ΔhycA ΔlacI (WDHL) strain with or without pH control. The correlation coefficient between the hydrogen production determined by gas chromatography and the hydrogen production estimated by the BPNN was 0.955. Results showed that the BPNN successfully estimated the hydrogen production using only on-line parameters in genetically modified E. coli fermentations either with or without pH control. This approach could be used for other hydrogen production systems.     

Thermodynamic assessment of an electrically-enhanced thermochemical hydrogen production (EETHP) concept for renewable hydrogen generation

A novel concept for coupling a thermochemical cycle with an electrochemical separation device for the generation of hydrogen from steam is reported and a thermodynamic analysis of the system is presented. In a conventional thermochemical cycle, an oxygen carrier material is thermally reduced, cooled, and then reoxidized in steam thereby generating hydrogen. However, this process often requires high temperatures (>1700 K) and/or low oxygen partial pressures (<0.001 atm) in order to meet thermodynamic requirements. Such extreme conditions can adversely affect the stability of the reactive oxides, reactor materials, and system efficiency. In our proposed technology, we seek to decrease the required reduction temperature by several hundred degrees Kelvin by relaxing the requirement for spontaneous oxidation reaction at atmospheric pressure. This is accomplished by incorporating a proton-conducting membrane (PCM) to separate hydrogen produced at equilibrium concentrations from reactant steam. We also suggest the use of mixed ionic-electronic conducting (MIEC) oxygen carrier materials that reduce through a continuum of oxidation states at lower temperatures (～1200 °C). This concept allows the generation of a high-quality hydrogen stream while avoiding the challenging high temperatures/low partial pressures required in conventional water-splitting reaction schemes.     

Prospects of green hydrogen in Poland: A techno-economic analysis using a Monte Carlo approach

The European Commission's plan to decarbonize the economy using innovative energy carriers has brought into question whether the national targets for developing electrolysis technologies are sufficiently ambitious to establish a local hydrogen production industry. While several research works have explored the economic viability of individual green hydrogen production and storage facilities in the Western European Member States, only a few studies have examined the prospects of large-scale green hydrogen production units in Poland. In this study, a Monte Carlo-based model is proposed and developed to investigate the underlying economic and technical factors that may impact the success of the Polish green hydrogen strategy. Moreover, it analyzes the economics of renewable hydrogen at different stages of technological development and market adoption. This is achieved by characterizing the local meteorological conditions of Polish NUTS-2 regions and comparing the levelized cost of hydrogen in such regions in 2020, 2030, and 2050. The results show the geographical locations where the deployment of large-scale hydrogen production units will be most cost effective.     

A novel process simulation model for hydrogen production via reforming of biomass gasification tar

Process modeling and simulation are very important for new designs and estimation of operating variables. This study describes a new process for the production of hydrogen from lignocellulosic biomass gasification tars. The main focus of this research is to increase hydrogen production and improve the overall energy efficiency of the process. In this study, Aspen HYSYS software was used for simulation. The integration structure presented in this research includes sections like tar reforming and ash separation (Ash), combined heat and power cycle (CHP), hydrogen sulfide removal unit (HRU), water-gas shift (WGS) reactor, and gas compression as well as hydrogen separation from a mixture of gases in pressure swing adsorption (PSA). It was found that the addition of CHP cycle and the use of the plug flow reactor (PFR) model, firstly, increased the overall energy efficiency of the process by 63% compared to 29.2% of the base process. Secondly it increased the amount of hydrogen production by 0.518 kmol (H2)/kmol Tar as compared with 0.475 of the base process. Process analysis also demonstrated that the integrated process of hydrogen production from biomass gasification tars is carbon neutral.     

Generation-IV reactors and nuclear hydrogen production

There are dozens of hydrogen production methods and techniques from many sources such as fossil fuels, renewable energy sources and nuclear energy in the literature. Thermo-chemical methods are more efficient at higher temperatures to produce large quantities of hydrogen. In this study, a comparative overview of Generation VI nuclear reactor types for major hydrogen production methods have been researched in the literature and suggestions have been carried out.This research work is addressing that both electric power cycle and hydrogen production based on nuclear technologies need to be developed. Generation IV nuclear reactors can provide hydrogen for a worldwide hydrogen economy. Both thermo-chemical and electrolysis (hybrid) processes in hydrogen production have a promising future, especially when integrated with Generation IV nuclear power plants. Efficient heat transfer is required for both high temperature thermodynamic cycles and the high temperature steam electrolysis. Hence, highly efficient heat exchanger designs are one of the key technologies for that purpose.     

Efficient solar hydrogen production by photocatalytic water splitting: From fundamental study to pilot demonstration

Photocatalytic water splitting with solar light is one of the most promising technologies for solar hydrogen production. From a systematic point of view, whether it is photocatalyst and reaction system development or the reactor-related design, the essentials could be summarized as: photon transfer limitations and mass transfer limitations (in the case of liquid phase reactions). Optimization of these two issues are therefore given special attention throughout our study. In this review, the state of the art for the research of photocatalytic hydrogen production, both outcomes and challenges in this field, were briefly reviewed. Research progress of our lab, from fundamental study of photocatalyst preparation to reactor configuration and pilot level demonstration, were introduced, showing the complete process of our effort for this technology to be economic viable in the near future. Our systematic and continuous study in this field lead to the development of a Compound Parabolic Concentrator (CPC) based photocatalytic hydrogen production solar rector for the first time. We have demonstrated the feasibility for efficient photocatalytic hydrogen production under direct solar light. The exiting challenges and difficulties for this technology to proceed from successful laboratory photocatalysis set-up up to an industrially relevant scale are also proposed. These issues have been the object of our research and would also be the direction of our study in future.     

Advances in catalysts for hydrogen production by methanolysis of sodium borohydride

Fossil energy is a major contributor to global greenhouse gases and air pollutants, causing serious environmental and health issues. In order to develop clean new energy as a substitute, catalytic methanolysis of sodium borohydride (NaBH₄) has become a hot topic in hydrogen energy field. In this work, the latest research development of hydrogen production by NaBH₄ methanolysis is comprehensively reviewed from the perspective of different types of catalysts, furthermore, the merits and demerits of these studies are analyzed, the comparison between various catalysts is also completed from the dimensions of hydrogen generation rate, apparent activation energy as well as durability, and the technical challenges the hydrogen production process may face and the corresponding recommendations are proposed. This review can provide enlightenment for the research and application of novel catalysts for the methanolysis of NaBH₄ and the development of efficient hydrogen production technology.     

Transition to a new era with light-based hydrogen production for a carbon-free society: An overview

This study discusses the transitional solutions with light-based hydrogen production for a carbon-free or low-carbon future. With a particular focus on the cutting-edge research activities at the Clean Energy Research Laboratory (CERL), some light-based innovative hydrogen production systems are discussed thoroughly. At the CERL, the main motivation is to achieve sustainability via a 3S approach, which is the source, system, and service. Therefore, clean, efficient, affordable, and reliable hydrogen production is seen as the first step towards the transition to a carbon-free future. With this goal in mind, the initial research activities at the CERL cover PV-electrolysis, photocatalysis, and photoelectrochemical cells for sustainable light-based hydrogen production. In the following steps, towards hybridization and system integration, various effective multigeneration systems are designed, built, and tested at the CERL. These multigeneration systems not only enhance the solar spectrum utilization, but also provide additional valuable system products such as electricity, heat, Cl₂, NaOH, clean water, and ammonia. Better resource utilization decreases system costs, enhances efficiencies, and certainly lowers the negative environmental footprint. The innovative hydrogen production systems designed at the CERL do not require additional chemicals like most of the photocatalytic systems, and as a result, they have less damage to the limited clean water resources of our planet. Besides, at the CERL, numerous novel systems are developed and tested to produce hydrogen from wastewaters. All of these systems are capable of producing outputs that are widely needed across the globe, which highlights the importance of the research currently taken place at the CERL.     

A review on hydrogen production using aluminum and aluminum alloys

The hydrogen economy has been identified as an alternative to substitute the non-sustainable fossil fuel based economy. Ongoing research is underway to develop environmentally friendly and economical hydrogen production technologies that are essential for the hydrogen economy. One of the promising ways to produce hydrogen is to use aluminum or its alloys to reduce water or hydrocarbons to hydrogen. This paper gives an overview on these aluminum-based hydrogen production methods, their limitations and challenges for commercialization. Also, a newly developed concept for cogeneration of hydrogen and electrical energy is discussed.