Ultra-pure hydrogen production via ammonia decomposition in a catalytic membrane reactor

In this work two alternatives are presented for increasing the purity of hydrogen produced in a membrane reactor for ammonia decomposition. It is experimentally demonstrated that either increasing the thickness of the membrane selective layer or using a small purification unit in the permeate of the membranes, ultra-pure hydrogen can be produced. Specifically, the results show that increasing the membrane thickness above 6 μm ultra-pure hydrogen can be obtained at pressures below 5 bar. A cheaper solution, however, consists in the use of an adsorption bed downstream the membrane reactor. In this way, ultra-pure hydrogen can be achieved with higher reactor pressures, lower temperatures and thinner membranes, which result in lower reactor costs. A possible process diagram is also reported showing that the regeneration of the adsorption bed can be done by exploiting the heat available in the system and thus introducing no additional heat sources.     

Supported Ni catalysts prepared from hydrotalcite-like compounds for the production of hydrogen by ammonia decomposition

Ni catalysts with high surface areas were prepared from Mg–Al hydrotalcite-like compounds containing Ni with different Mg-to-Al ratios for the production of hydrogen via ammonia decomposition. At atomic ratios of Mg-to-Al from 3:1 to 6:1, Ni reduction was greater than 90%, and the amounts of Ni⁰ exposed were kept at more than 200 μmol g^?1. With the increase in Mg-to-Al ratio, turnover frequency was increased due to an increase in the basicity of the support. Of the catalysts examined, Ni_MgAl(6:1) exhibited the highest NH₃ conversion, which was attributed to its relatively high basicity and large amount of Ni⁰ exposed.     

3D simulation of hydrogen production by ammonia decomposition in a catalytic membrane reactor

Ammonia decomposition in an integrated Catalytic Membrane Reactor for hydrogen production was studied by numerical simulation. The process is based on anhydrous NH₃ thermal dissociation inside a small size reactor (30 cm³), filled by a Ni/Al₂O₃ catalyst. The reaction is promoted by the presence of seven Pd coated tubular membranes about 203 mm long, with an outer diameter of 1.98 mm, which shift the NH₃ decomposition towards the products by removing hydrogen from the reaction area. The system fluid-dynamics was implemented into a 2D and 3D geometrical model. Ammonia cracking reaction over the Ni/Al₂O₃ catalyst was simulated using the Temkin-Pyzhev equation.Introductory 2D simulations were first carried out for a hypothetic system without membranes. Because of reactor axial symmetry, different operative pressures, temperatures and input flows were evaluated. These introductory results showed an excellent ammonia conversion at 550 °C and 0.2 MPa for an input flow of 1.1 mg/s, with a residual NH₃ of only a few ppm. 3D simulations were then carried out for the system with membranes. Hydrogen adsorption throughout the membranes has been modeled using the Sievert’s law for the dissociative hydrogen flux. Several runs have been carried out at 1 MPa changing the temperature between 500 °C and 600 °C to point out the conditions for which the permeated hydrogen flux is the highest. With temperatures higher than 550 °C we obtained an almost complete ammonia conversion already before the membrane area. The working temperature of 550 °C resulted to be the most suitable for the reactor geometry. A good matching between membrane permeation and ammonia decomposition was obtained for an NH₃ input flow rate of 2.8 mg/s. Ammonia reaction shift due to the presence of H₂ permeable membranes in the reactor significantly fostered the dissociation: for the 550 °C case we obtained a conversion rate improvement of almost 18%.     

Freeze-dried ammonia borane-polyethylene oxide composites: Phase behaviour and hydrogen release

A solid-state hydrogen storage material comprising ammonia borane (AB) and polyethylene oxide (PEO) has been produced by freeze-drying from aqueous solutions from 0% to 100% AB by mass. The phase mixing behaviour of AB and PEO has been investigated using X-ray diffraction which shows that a new ‘intermediate’ crystalline phase exists, different from both AB and PEO, as observed in our previous work (Nathanson et al., 2015). It is suggested that hydrogen bonding interactions between the ethereal oxygen atom (–O–) in the PEO backbone and the protic hydrogen atoms attached to the nitrogen atom (N–H) of AB molecules promote the formation of a reaction intermediate, leading to lowered hydrogen release temperatures in the composites, compared to neat AB. PEO also acts to significantly reduce the foaming of AB during hydrogen release. A temperature-composition phase diagram has been produced for the AB-PEO system to show the relationship between phase mixing and hydrogen release.     

Tube-wall catalytic membrane reactor for hydrogen production by low-temperature ammonia decomposition

Ammonia has attracted great interest as a chemical hydrogen carrier. However, ammonia decomposition is limited kinetically rather than thermodynamically below 400 °C. We developed a tube-wall catalytic membrane reactor that could decompose ammonia with high conversion even at temperatures below 400 °C. The reactor had excellent heat transfer characteristics, and thus nearly 100% conversion for an NH3 feed of 10 mL/min at 375 °C was achieved with a 2-μm-thick palladium composite membrane, and hydrogen removal from the decomposition side resulted in a large kinetic acceleration.     

Zn-MOF assisted dehydrogenation of ammonia borane: Enhanced kinetics and clean hydrogen generation

We report controllable and enhanced hydrogen release kinetics at reduced temperatures in ammonia borane (AB) catalyzed by Zn-MOF-74. AB is loaded into the unsaturated Zn-metal coordinated one-dimensional hexagonal open nanopores of MOF-74 (ABMOF) via solution infiltration. The ABMOF system provides clean hydrogen by suppressing the release of detrimental volatile byproducts such as ammonia, borazine and diborane. These byproducts prevent the direct use of AB as a hydrogen source for polymer electrolyte membrane fuel cell applications. The H₂ release temperature, kinetics, and byproduct generation are dependent on the amount of AB loading. We show that nanoconfinement of AB and its interaction with the active Zn-metal centers in MOF are important in promoting efficient and clean hydrogen generation.     

High and rapid hydrogen release from thermolysis of ammonia borane near PEM fuel cell operating temperatures

Ammonia borane (NH₃BH₃, AB), containing 19.6 wt % hydrogen, is a promising hydrogen storage material for use in proton exchange membrane fuel cell (PEM FC) powered vehicles. Our experiments demonstrate the highest H₂ yield (∼14 wt %, 2.15 H₂ equivalent) values obtained by neat AB thermolysis near PEM FC operating temperatures, along with rapid kinetics, without the use of either catalyst or additives. It was also found that only trace amount of ammonia (<10 ppm) is produced during dehydrogenation reaction and spent AB products are polyborazylene-like species, which can be efficiently regenerated using currently demonstrated methods. The results indicate that our proposed method is the most promising one available in the literature to-date for hydrogen storage, and could be used in PEM FC based vehicle applications.     

Flexible production of green hydrogen and ammonia from variable solar and wind energy: Case study of Chile and Argentina

We report a techno-economic modelling for the flexible production of hydrogen and ammonia from water and optimally combined solar and wind energy. We use hourly data in four locations with world-class solar in the Atacama desert and wind in Patagonia steppes. We find that hybridization of wind and solar can reduce hydrogen production costs by a few percents, when the effect of increasing the load factor on the electrolyser overweighs the electricity cost increase. For ammonia production, the gains by hybridization can be substantially larger, because it reduces the power variability, which is costly, due to the need for intermediate storage of hydrogen between the flexible electrolyser and the less flexible ammonia synthesis unit. Our modelling reveals the crucial role in the synthesis of flexibility, which cuts the cost of variability, especially for the more variable wind power. Our estimated near-term production costs for green hydrogen, around 2 USD/kg, and green ammonia, below 500 USD/t, are encouragingly close to competitiveness against fossil-fuel alternatives.     

COx-free hydrogen production from ammonia decomposition over sepiolite-supported nickel catalysts

Sepiolite, a clay mineral, was utilized as a support for nickel-based catalysts for CO_x-free hydrogen production from ammonia decomposition. First, the physical and chemical properties of sepiolite were changed by calcining it at temperatures varying from 500 to 1000 °C, then nickel was impregnated on these calcined supports and tested for ammonia decomposition at various temperatures following reduction at 650 °C. Results indicated that even though the catalysts contained almost the same amount of nickel, they showed different hydrogen production performance. Detailed characterization of the catalysts before and after reaction illustrated that the support obtained by calcining sepiolite at 700 °C shows good basic properties with a high surface area offering a high degree of nickel dispersion. These properties lead to promising hydrogen production rates which are on par, if not higher, than most of the nickel-based catalysts prepared on supports, which are either not cheap or require tedious preparation procedures.     

On-board hydrogen storage and production: An application of ammonia electrolysis

On-board hydrogen storage and production via ammonia electrolysis was evaluated to determine whether the process was feasible using galvanostatic studies between an ammonia electrolytic cell (AEC) and a breathable proton exchange membrane fuel cell (PEMFC). Hydrogen-dense liquid ammonia stored at ambient temperature and pressure is an excellent source for hydrogen storage. This hydrogen is released from ammonia through electrolysis, which theoretically consumes 95% less energy than water electrolysis; 1.55 Wh g⁻¹ H₂ is required for ammonia electrolysis and 33 Wh g⁻¹ H₂ for water electrolysis. An ammonia electrolytic cell (AEC), comprised of carbon fiber paper (CFP) electrodes supported by Ti foil and deposited with Pt-Ir, was designed and constructed for electrolyzing an alkaline ammonia solution. Hydrogen from the cathode compartment of the AEC was fed to a polymer exchange membrane fuel cell (PEMFC). In terms of electric energy, input to the AEC was less than the output from the PEMFC yielding net electrical energies as high as 9.7 ± 1.1 Wh g⁻¹ H₂ while maintaining H₂ production equivalent to consumption.     

Thermal decomposition of alkaline-earth metal hydride and ammonia borane composites

We demonstrate a method to improve the promising hydrogen storage capabilities of ammonia borane by making composites with alkaline-earth metal hydrides using ball-milling technique. The ball-milling for the mixtures of alkaline-earth metal hydride (MgH₂ or CaH₂) and ammonia borane (AB) yields a destabilization compared with the ingredient of the mixture, showing the hydrogen capacity of 8.7 and 5.8 mass% at easily accessible dehydrogenation peak temperatures of 78 and 72 °C, respectively, without the unwanted by-product borazine. Through detailed analyses on the dehydrogenation performance of the composite at various ratios in the hydride and AB, we proposed a different chemical activation mechanism from that in the LiH/AB and NaH/AB systems reported in a previous literature.     

High and rapid hydrogen release from thermolysis of ammonia borane near PEM fuel cell operating temperatures: Effect of quartz wool

Ammonia borane (NH₃BH₃, AB), containing 19.6 wt% hydrogen, is a promising hydrogen storage material for use in proton exchange membrane fuel cell (PEM FC) powered vehicles. We recently demonstrated that using quartz wool, the highest H₂ yield (2.1–2.3H₂ equivalent) values were obtained by neat AB thermolysis near PEM FC operating temperatures, along with rapid kinetics, without the use of either catalyst or chemical additives. It was found that quartz wool minimizes sample expansion and facilitates the production of diamoniate of diborane (DADB), which is a key intermediate for the release of hydrogen from AB. It was also found that only trace amount of ammonia (<10 ppm) is produced during dehydrogenation reaction and spent AB products are found to be polyborazylene-like species, which can be efficiently regenerated using currently demonstrated methods. The results indicate that our proposed method is the most promising one available in the literature to-date for hydrogen storage, and could be used in PEM FC based vehicle applications.     

Effect of boric acid on thermal dehydrogenation of ammonia borane: Mechanistic studies

Ammonia borane (AB, NH₃BH₃) is a promising hydrogen storage material for use in proton exchange membrane (PEM) fuel cell applications. In this study, the effect of boric acid on AB dehydrogenation was investigated. Our study shows that boric acid is a promising additive to decrease onset temperature as well as to enhance hydrogen release kinetics for AB thermolysis. With heating, boric acid forms tetrahydroxyborate ion along with some water released from boric acid itself. It is believed that this ion serves as Lewis acid which catalyzes AB dehydrogenation. Using boric acid, we obtained high H₂ yield (11.5 wt% overall H₂ yield, 2.23 H₂ equivalent) at 85 °C, PEM fuel cell operating temperatures, along with rapid kinetics. In addition, only trace amount of NH₃ (20–30 ppm) was detected in the gaseous product. The spent AB solid product was found to be polyborazylene-like species. The results suggest that the addition of boric acid to AB is promising for hydrogen storage, and could be used in PEM fuel cell based vehicles.     

Single-step synthesized dual-layer hollow fiber membrane reactor for on-site hydrogen production through ammonia decomposition

On-site hydrogen production via catalytic ammonia decomposition presents an attractive pathway to realize H₂ economy and to mitigate the risk associated with storing large amounts of H₂. This work reports the synthesis and characterization of a dual-layer hollow fiber catalytic membrane reactor for simultaneous NH₃ decomposition and H₂ permeation application. Such hollow fiber was synthesized via single-step co-extrusion and co-sintering method and constitutes of 26 μm-thick mixed protonic-electronic conducting Nd_5.5Mo_0.5W_0.5O_11.25-δ (NMW) dense H₂ separation layer and Nd_5.5Mo_0.5W_0.5O_11.25-δ-Ni (NMW-Ni) porous catalytic support. This dual-layer NMW/NMW-Ni hollow fiber exhibited H₂ permeation flux of 0.26 mL cm⁻² min⁻¹ at 900 °C when 50 mL min⁻¹ of 50 vol% H₂ in He was used as feed gas and 50 mL min⁻¹ N₂ was used as sweep gas. Membrane reactor based on dual-layer NMW/NMW-Ni hollow fiber achieved NH₃ conversion of 99% at 750 °C, which was 24% higher relative to the packed-bed reactor with the same reactor volume. Such higher conversion was enabled by concurrent H₂ extraction out of the membrane reactor during the reaction. This membrane reactor also maintained stable NH₃ conversion and H₂ permeation flux as well as structure integrity over 75 h of reaction at 750 °C.     

Fe-based catalyst derived from MgFe-LDH: Very efficient yet simply obtainable for hydrogen production via ammonia decomposition

The current study provided the first example to develop the Fe-based catalyst for CO_x-free hydrogen production via ammonia decomposition through the unique MgFe-layered double hydroxides (MgFe-LDHs) of different stoichiometric Mg/Fe ratio. The so obtained Fe-based catalyst is low-cost, readily obtainable, and environmentally friendly. Structurally, the Fe(FeN_x) species are 3D-isolated by the nano-MgO entities, improving anti-sintering potential of Fe(FeN_x); and electronically, the Fe (FeN_x) species are promoted by the nano-MgO matrix, showing the strongest promoting effect of MgO on Fe(FeN_x). At a GHSV_NH3 of 150,000 mL g_cat⁻¹ h⁻¹, the current N–Mg_5.3FeO_m catalyst can give an outstanding H₂ formation rate of 9.83 mol g_cat⁻¹ h⁻¹ at 680 °C and a TOF_H2 = 2.19 s⁻¹ at 530 °C. The influence of Mg/Fe constitution on catalyst structure, surface property, and performance was systematically investigated. The in-situ ammonia treatment was superior to the usually adopted hydrogen pre-reduction for the Fe–Mg oxide precursor, leading to easy development of small sized FeN_x specimen and activity enhancement.     

Liquid hydrogen,methylcyclohexane, and ammonia as potential hydrogen storage: Comparison review

Among the several candidates of hydrogen (H₂) storage, liquid H₂, methylcyclohexane (MCH), and ammonia (NH₃) are considered as potential hydrogen carriers, especially in Japan, in terms of their characteristics, application feasibility, and economic performance. In addition, as the main mover in the introduction of H₂, Japan has focused on the storage of H₂, which can be categorized into these three methods. Each of them has advantages and disadvantages compared to the other. Liquid H₂ faces challenges in the huge energy consumption that occurs during liquefaction and in the loss of H₂ through boil-off during storage. MCH has its main obstacles in requiring a large amount of energy in dehydrogenation. Finally, NH₃ encounters high energy demand in both synthesis and decomposition (if required). In terms of energy efficiency, NH₃ is predicted to have the highest total energy efficiency, followed by liquid H₂, and MCH. In addition, from the calculation of cost, NH₃ with direct utilization (without decomposition) is considered to have the highest feasibility for massive adoption, as it shows the lowest cost (20–22 JPY·Nm³-H₂ in 2050), which is close to the government target of H₂ cost (20 JPY·Nm³-H₂ in 2050). However, in the case that highly pure H₂ (such as for fuel cell) is needed, liquid H₂ looks to be promising (24–25 JPY·Nm³-H₂ in 2050), compared with MCH and NH₃ with decomposition and purification.     

Influence of basic dopants on the activity of Ru/Pr6O11 for hydrogen production by ammonia decomposition

Basic oxides such as alkali metal oxides, alkaline earth metal oxides, and rare earth oxides were added to Ru/Pr₆O₁₁, and the activity of the catalysts with respect to hydrogen production by ammonia decomposition was investigated. Ru/Pr₆O₁₁ doped with alkali metal oxides, except for Li₂O, achieved higher NH₃ conversions than bare Ru/Pr₆O₁₁. Cs₂O, the most basic of the alkali metal oxides, was the most effective dopant. In contrast, other dopants with lower basicity than the alkali metal oxides achieved lower NH₃ conversions than bare Ru/Pr₆O₁₁. Changing the Cs/Ru molar ratio revealed that the best Cs/Ru ratio was 0.5–2; the reaction was effectively promoted without negative effects from coverage of the Ru surface by the Cs₂O. Varying the order of loading the Ru and Cs₂O onto Pr₆O₁₁ revealed that loading Ru onto Cs₂O/Pr₆O₁₁ was an effective way to enhance NH₃ conversion, and coverage of the Ru surface was reduced.     

Analysis of ammonia decomposition reactor to generate hydrogen for fuel cell applications

In this paper, reaction engineering principles are utilized to analyze process conditions for producing sufficient hydrogen in an ammonia decomposition reactor for generating net power of 100 W in a fuel cell. It is shown that operating the reactor adiabatically results in a sharp decrease in temperature due to endothermic reaction, which results in low conversion of ammonia. For this reason, the reactor is heated electrically to provide heat for the endothermic reactions. It is observed that when the reactor is operated non-adiabatically, it is possible to get over 99.5% conversion of ammonia. The weight of absorbent to reduce ammonia to ppb levels is calculated. An energy balance on the reactor exit gas indicates that there is sufficient heat available to vaporize enough water to achieve 100% relative humidity in the fuel cell. A suitable fuel cell stack is designed and it is shown that this stack is able to provide the necessary power to electrically heat the reactor and produce net power of 100 W.     

Transient thermodynamic analysis of a novel integrated ammonia production,storage and hydrogen production system

A transient thermodynamic analysis is reported of a novel chemical hydrogen storage system using energy and exergy approaches. The hydrogen is stored chemically in ammonia using the proposed hydrogen storage system and recovered via the electrochemical decomposition of ammonia through an ammonia electrolyzer. The proposed hydrogen storage system is based on a novel subzero ammonia production reactor. A single stage refrigeration system maintains the ammonia production reactor at a temperature of −10 °C. The energy and exergy efficiencies of the proposed system are 85.6% and 85.3% respectively. The proposed system consumes 34.0 kJ of work through the process of storing 1 mol of hydrogen and recovering it using the ammonia electrolyzer. The system is simulated for filling 30,000 L of ammonia at a pressure of 5 bar, and the system was able to store 7500 kg of ammonia in a liquid state (1% vapor) in 1500 s. The system consumes nearly 45.3 GJ of energy to store the 7500 kg of ammonia and to decompose it to reproduce the stored hydrogen during the discharge phase.     

Catalyst support effect on ammonia decomposition over Ni/MgAl2O4 towards hydrogen production

Ammonia is a prospective fuel for hydrogen storage and production, but its application is limited by the high cost of the catalysts (Ru, etc.) to decompose NH₃. Decomposing ammonia using non-precious Ni as catalysts can therefore improve its prospects to produce hydrogen. This work proposes several Ni/MgAl₂O₄ with the support properties tuned and investigates the support effect on the catalytic performance. Ni/MgAl₂O₄-LDH shows high NH₃ conversion (～88.7%) and H₂ production rate (～1782.6 mmol g^?1 h^?1) at 30,000 L. kg^?1 h^?1 and 600 °C, which is 1.68 times as large as that of Ni/MgAl₂O₄-MM. The performance remains stable over 30 h. The characterizations manifest that the high specific surface area of Ni/MgAl₂O₄-LDH can introduce highly dispersed Ni on the surface. Kinetics analysis implies promoted NH₃ decomposition reaction and alleviated H₂ poisoning for Ni/MgAl₂O₄-LDH. A roughly linear relationship is obtained by fitting the curves of dispersed Ni on the surface vs the reaction orders regarding H₂ and NH₃. This indicates that enhanced NH₃ decomposition performance can be ascribed to the strengthened NH₃ decomposition reaction and weakened H₂ poisoning by the highly dispersed Ni on the MgAl₂O₄-LDH surface. This work provides an opportunity to develop highly active and cost-effective catalysts to produce hydrogen via NH₃ decomposition.