| Affiliation: | 1. Robert Frederick Smith School of Chemical and Biomolecular Engineering, Cornell University, Ithaca, New York, USA Contribution: Data curation (equal), Formal analysis (equal), Investigation (equal), Methodology (equal), Validation (equal), Visualization (equal), Writing - original draft (lead), Writing - review & editing (equal);2. Robert Frederick Smith School of Chemical and Biomolecular Engineering, Cornell University, Ithaca, New York, USA |
| Abstract: | This article addresses the sustainable design of hydrogen (H2) production systems that integrate brown and blue pathways with green hydrogen infrastructure. We develop a systematic framework to simultaneously optimize the process superstructure and operating conditions of steam methane reforming (SMR)-based hydrogen production systems. A comprehensive superstructure that integrates SMR with multiple carbon dioxide capture technologies, electrolyzers, fuel cells, and working fluids in the organic rankine cycle is proposed under varying operating conditions. A life cycle optimization model is then developed by integrating superstructure optimization, life cycle assessment approach, techno-economic assessment, and process optimization using extensive process simulation models and formulated as a mixed-integer nonlinear program. We find that the optimal unit-levelized cost of hydrogen ranges from $1.49 to $3.18 per kg H2. Moreover, the most environmentally friendly process attains net-zero life cycle greenhouse gas emissions compared to 10.55 kg CO2-eq per kg H2 for the most economically competitive process design. |
