Basics of Hydrogen Technology
Basics of Hydrogen Technology
HYDROGEN
TECHNOLOGY
Dr. O.P Agarwal, Pawan Mulukutla and Krishnaveni Malladi
5.0 CONCLUSION 25
LIST OF ABBREVIATIONS
1. ATR - Auto - Thermal Reforming
2. BG - Biomass Gasification
3. CCS - Carbon Capture and Storage
4. CCUS - Carbon Capture Utilization and Storage
5. CG - Coal Gasification
6. EAF – Electric Arc Furnaces
7. GHGs - Greenhouse Gases
8. GWP - Global Warming Potential
9. MMT – Million Metric Tonnes
10. Mtoe - Million tonnes of oil equivalent
11. PEM - Proton Exchange Membrane
12. POX - Partial Oxidation
13. SMR - Steam Methane Reforming
14. SOE - Solid Oxide Electrolyzer
15. TRL - Technology Readiness Level
LIST OF FIGURES AND TABLES
Figure 1: World energy consumption in quadrillion Btu 6
Figure 2: Energy mix of India in 2019 and 2040 (In %) 8
Figure 3:
India’s power generation mix, 2000-2040 9
Figure 4: Energy related CO2 emissions by sectors 9
Figure 5: Cost of production (in INR) of 1000 MJ of energy, WRI India estimates 12
Figure 6: SMR schematic representation 14
Figure 7: Coal gasification 15
Figure 8: Schematic diagram of electrolysis process 16
Figure 9: Four types of electrolysis in hydrogen production 16
Figure 10: Biomass gasification 17
Figure 11: Production cost of hydrogen 18
Figure 12: Hydrogen value chain 19
Figure 13: End use of hydrogen 22
4
1.0 THE GLOBAL triggering extreme weather changes. According to
projections, the global population is set to increase by
ROLE OF HYDROGEN globe, is the main cause of the rise in GHG levels.
Studies1,2,3,4,5 indicate that between 2018 and 2050,
global energy consumption will rise by nearly 50%.
The increasing levels of emissions of carbon dioxide The industrial sector, which includes refining, mining,
(CO2) and other greenhouse gases (GHGs) generated manufacturing, agriculture, and construction,
from human activities have caused global surface and accounts for the largest share of energy consumption
ocean temperatures to rise at unparalleled rates, among all end-use sectors.
30% increase
in global industrial energy consumption, reaching about
315 quadrillion British thermal units (Btu) by 2050.
40% increase
in transportation energy consumption during this period.
65% increase
in energy consumption during this period, from 91 quadrillion Btu
to 139 quadrillion Btu, ascribed to urbanization, rising incomes,
and increased access to electricity in the building sector.
1000
history projections
non-OECD
800
Price (Thousand Yuan)
600
400
OECD
200
0
2010 2020 2030 2040 2050
Fossil fuels, which are the largest energy source, contributing to at least 5 million7 deaths worldwide
constituted 64% of the global energy consumed in every year. Fossil-based energy consumption must be
2018. In addition to being the largest driver of climate reduced by decarbonizing energy sectors and
change, burning fossil fuels and organic matter is constituting an energy mix dominated by renewable
harmful to human health, with air pollution alone technologies.
PARIS
AGREEMENT
6
The electrification of end-use sectors that results in While the share of renewables such as wind and solar
increased use of electricity in buildings, industry and in the overall energy mix is expected to rise, several
transport and expanded production and use of green challenges need to be addressed, key among them
hydrogen, synthetic fuels, and feedstocks to pursue being the non-availability of solar insolation for a
indirect electrification are ways of reducing fossil fuel substantial part of the calendar day, the variability
burning. The targeted use of sustainably sourced owing to lack of uniformity in wind and solar
biomass, particularly in place of high-energy density insolation and the barriers in energy storage. Owing
fuels, such as those used in aviation and other to its potential for application in multiple form factors,
transport modes or in greening gas grids, is also hydrogen presents great prospects for meeting the
being discussed. current challenges.
By 2050
electiricity would be the primary energy source with over 50% (direct)
total final energy use, up from 20% today9.
Renewables 13
3.4
3
Hydro 3.9
Nuclear 2
1.09
Coal 50
56
Gas 7
6
25
Oil 29.5
0 10 20 30 40 50 60
Percentage
2040 2019
8
Figure 3 | India’s power generation mix, 2000-204014
75%
50%
25%
0
2000 2010 2020 2030 2040
India’s growing demand for energy, its commitment to emphasize the adoption of clean energy substitutes
the Paris Agreement, and the goal to reduce GHG and increasing efficiencies of the existing energy
emissions by a third by 2030 are areas that require sources, policymakers must also accelerate efforts to
considerable attention. Its current annual GHG derisk import of critical items such as oil and gas,
emissions stand at 3.6 G tons of CO2 equivalent (see given the significant forex outflow and the security
sectoral emissions in Figure 4). While current efforts implications of the projected imports.
CO2
2019 Power Sector
Building Sector
6% 43%
Transport Sector
14%
New models of energy auction have seen rates per unit raises exciting possibilities of using alternate pathways
of electricity hit a rock bottom price of about INR 2 per of storing, using and reusing energy to meet the
kWh unit (~2.67 cents/kWh unit). Although solar demands of various sectors. One such pathway is the
energy is green and has almost zero carbon emissions, utilization of hydrogen as an energy carrier. The
it is an unreliable source. In order to overcome this solar-hydrogen cycle has the potential to lead the
limitation, the multiple uses of hydrogen generated country to a more sustainable energy future. Hydrogen
from green sources of energy can be explored technology promises to be a solution for various
alongside the existing low carbon hydrogen streams. sectors. Owing to its application in the transportation
This would also help lower the import bill. sector as fuel and storage of energy, hydrogen must be
explored as a policy tool for strategic investment as
DEVELOP A GREEN pricing and other economics in place, hydrogen has the
potential to replace fossil fuels to a large extent and
10
4.0 WHAT IS HYDROGEN?
1 Atomic Number
Element Symbol
H
Hydrogen
1.00794 Atomic Weight
Hydrogen is colourless and odorless17, with the lowest density among all gases. It is a gas at normal
temperature and pressure but condenses to liquid at -423° Fahrenheit or -253° Celsius. Hydrogen
combines with other elements to form compounds, including common ones such as water (H2O),
ammonia (NH3), methane (CH4), glucose (C6H12O6), hydrogen peroxide (H2O2) and hydrochloric acid (HCl).
Hydrogen has three isotopes, namely protium (commonly called hydrogen), deuterium and tritium.
Figure 5 | Cost of production (in INR) of 1,000 MJ of energy, WRI India estimates
Basic Cost
12
4.3 PRODUCTION OF HYDROGEN gas accounts for 48% of the production of hydrogen, oil
30%, coal 18%, and electrolysis 4%. The different
processes used for producing hydrogen are
The global demand for pure hydrogen increased, from
thermochemical, electrolytic, direct solar water
less than 20 million metric tons (MMT) in 1975 to
splitting, biological process, and nuclear23.
more than 70 MMT in 2019. The current demand for
hydrogen is fulfilled mainly by fossil fuels, including
Although colorless and invisible, hydrogen has been
natural gas, oil and coal. These fuels represent the
color-coded by the energy industry to differentiate it
cheapest pathway, allowing the cost of hydrogen to
on the basis of the source or process by which it is
vary between USD 2 and 4 per kg22. Of these, natural
produced24.
Anion Exchange Membrane Solid polymer membrane made of polymer backbone and cationic groups
Biological Process (Using Microbial mass conversion Hydrolysis and fermentation of biomass
microbes, the organic matter
is decomposed in presence of
Photobiological Microorganisms, such as green microalgae or cyanobacteria, use sunlight
sunlight)
NG feed SMR H2
WGS 1 PSA
reactor
Fuel gas
Tail gas
2
14
4.3.2 PARTIAL OXIDATION 4.3.3 COAL GASIFICATION
Hydrocarbons, especially methane, in natural gas Carbon-based feedstock, or coal, is converted into
react with oxygen to produce CO2 and water. This syngas - a mixture of CO, hydrogen steam and oxygen
process is non-catalytic and exothermic. The reaction - in a gasifier in the presence of steam and oxygen at a
occurs in two steps at a temperature of 1300-1500°C 28
very high temperature and moderate pressure.
with partial oxidation of methane and water-gas shift. Depending on the gasification technology used, some
This process is much faster than steam reforming and quantities of water, CO2 and methane can be produced
requires a smaller reactor vessel with the production alongside syngas30. For the production of hydrogen,
of heat. This reaction produces three molecules of syngas is moved to a water-gas shift reactor, whereby
hydrogen for every molecule of methane. This process CO in the gas is reacted with water to produce
is commercially available and has an efficiency of additional hydrogen and CO2, which are then
60-70%. As compared with SMR (H2: CO = 3:1), more separated, producing about two hydrogen molecules
CO is produced (H2: CO =1:1 or 2:1) than hydrogen . 29
and three molecules of carbon.
Gasifying agent:
air, steam, oxygen
Cathode Anode
– +
Hydrogen Oxygen
Hydrogen Oxygen
Bubbles Bubbles
Electrolyte Solution
■ Uses aqueous KOH / NaOH ■ Uses polysulphonated ■ Uses solid ceramic ■ Uses ionsomer membrane
solution as conduting membrane for proton exchange membrane ■ @ Demonstration scale
membrane and platinum, iridium oxide as ■ @ R & D scale ■ Operates at 50–60°C
■ Matured technology and electrocatalyst ■ Operates at 500–850°C ■ Efficiency of 55-69%
commercially available ■ Operating at small pilot ■ Efficiency of 74-80%
■ Operates at 30–80°C plants
temperature ■ Operates at 30–80°C
■ Efficiency of 63-70% temperature
■ Efficiency of 55-60%
16
Table 3 | Comparison of types of electrolyzers
Sl. no. Type of Electrolyzer Purity of H2 gas (%) Hydrogen output (kgh-1) Stack lifetime ('000 hours) Capital cost (Euro/ kW)
Biomass gasification (BG) allows the conversion of Photolysis: Photolysis is the process of splitting
organic feedstock into useful energy form, such as heat water molecules into hydrogen and oxygen using light.
and electricity. In BG, the combustion of organic Photolysis can be brought on either by a photobiologi-
matter under controlled oxygen results in the cal or photoelectrochemical process. The photobiologi-
production of combustible gases, such as CO, hydrogen cal process involves the production of hydrogen using
and traces of methane. This mixture is called syngas . 36
microorganisms such as green algae in the presence of
Biomass is available from a wide range of sources, such light, whereas in the photoelectrochemical process, a
as animal waste, municipal solid waste, crop residue, catalyst is used.
short-rotation woody crops, agricultural waste,
sawdust, aquatic plants, short-rotation herbaceous Auto Thermal Reformation: Auto thermal reform-
species, waste paper and corn. Approximately 13-14 Kg ing (ATR), a combination of steam reforming and
of bone dry biomass is required to produce 1 Kg of partial oxidation, is a promising technology for the
hydrogen . The gasification process typically suffers
37 production of low-cost and highly reliable hydrogen.
from low thermal efficiency because The operational temperature is 950-1050oC, and a
of high moisture content. pressure of 30-50 bar is required. ATR can also be
shut down and started rapidly while producing more
hydrogen than POX alone.
Figure 10 | Biomass gasification
Syngas
Gasifier
Oxygen rich steam
Memberane
separator
Wastes
(ash, inorganics, tar)
BASICS OF HYDROGEN TECHNOLOGY | 17
4.4 ECONOMIC ASPECTS OF 4.5 HYDROGEN VALUE CHAIN
PRODUCING HYDROGEN USING
DIFFERENT PATHWAYS There are four main stages in the hydrogen value
chain: production, storage, transportation, and
utilization. These four states interconnect the entire
The costs of producing hydrogen vary significantly
hydrogen energy system. The selection of the hydrogen
between regions due to the variability in the cost of the
production process depends on the availability of
resources required. Natural gas and coal are abun-
feedstock, the type of energy and the end-user
dantly found only in select areas, where it is cheaper.
requirements.
Similarly, costs for generating electricity vary from
region to region, thereby influencing the cost of raw
material required for the production of hydrogen.
Presently, producing hydrogen using natural gas
without carbon capture technology is the most eco-
nomical route worldwide. Production through electrol-
ysis depends on the cost of electricity and electrolyzer
used. These methods are currently expensive as
compared with the natural gas-based production
process without carbon capture storage (CCS). Figure
11 illustrates the cost of hydrogen when produced
using different methods38.
1000
800
600
400 813
200 433
245 258
150
0
Steam Methane Coal Biomass Biomass Electrolyzer
Reforming Gascification Gascification Microbial Alkaline
Rs/kg
18
Figure 12 | Hydrogen value chain
Electrolysis Membrane
Green pathway
High Temperature
WIND
ELECTRICITY
Biomass Gascification
Hydrogen Gas (H2)
(WET)
HYBRID
High Temperature
GRID Grey, Blue
Pathway
Steam Methane
Reforming (SMR)
Conventional Methods
Coal
Gascification (CG)
NH3/Liquified Hs
Chemicals & Fertilizers
H2 Gas
Cement
H2 Gas
Power
4.7 STORAGE & TRANSPORTATION form by using metal hydride compounds is ongoing.
Table 5 presents a comparison of the different storage
System Source Readiness Level Efficiency (%) Cost USD/Kg of H2 GWP (Kg CO2 /Kg H2)
Steam reforming without CCS Fossil fuel (Hydrocarbon) 9 70-80% 1.5 - 2.5 9 -10
20
Table 5 | Storage methods for hydrogen
Pressurized storage Matured technology, high efficiency Specialized materials required to withstand high pressure
Cryogenic Higher liquid density, suitable for large quantities High liquefaction costs, boiloff gas management and expensive
materials required
Metal hydride Relatively high density, modular operation Emerging technology, not commercialized, heavier to handle
Hydrogen can be made available at the retail point Pipelines (existing or new), although a sophisticated
using distribution options such as pressurised technology, requires more capital expenditure and is
containers, liquified containers, pipelines, and onsite more suited for large volumes. A simpler option is to
production. Road transport using pressurised have onsite hydrogen generation, which eliminates the
containers is the normal way of transporting cost of transportation. Water electrolysis is most
hydrogen, but liquefaction of hydrogen for transport suitable for onsite production as it is more scalable and
results in a significant increase in its energy density emission-free.
and allows for carrying upto 10 times more hydrogen.
Pressurized container or cylinders Limited quantity can be transported Specialized material to withstand the pressure and weight
Cryogenic Liquefaction costs are high Require special material to carry and to boiloff to be addressed
4.8.1 FEEDSTOCK FOR INDUSTRIES 837 MMT43. A significant reduction in these emissions
As more industries plan to decarbonize and reduce is required to meet the global carbon reduction targets
their associated process-related industrial emissions and India’s own NDCs. With more than 970 steel
by 2050, the demand for hydrogen, especially green, is plants, India is currently the world’s second-largest
expected to increase. The following sub-sections producer and third-largest consumer of steel. Steel can
present the scope for hydrogen usage in harder-to- be produced either by using an integrated blast
22
hydrogen used in the production of crude steel in the carbon footprint significantly.
DRI method results in a reduction in CO2 emission by
24 kgs44. Currently, only ~7%45 of primary steel is Methanol too is an important chemical, which can be
produced using the DRI method and hydrogen must be produced by hydrogenating hydrogen (sourced from
used as substitute and its share increased over time to fossil fuel) with CO2 (biomass or organic matter).
reduce the carbon footprint in steel production. Green hydrogen oxygenated with biomass CO2
produces green methanol, which is used for
formaldehyde and fuel applications and as an
4.8.1B REFINERIES
intermediary in the production of high-value
Crude oil accounts for approximately 30% of the
chemicals.
primary energy demand in the country, with more
than 80% of it being imported (IEA, 2020). Hydrogen
is used primarily to remove impurities such as sulphur 4.8.1D CEMENT
from crude oil. Stricter regulations on sulphur has led The cement industry is highly energy-intensive and a
to increased demand for hydrogen even as demand for major emitter of CO2 globally. India’s cement industry,
diesel and petrol has increased. Going by the existing on the technological front, has largely adopted modern
policies, by 2030, the demand for hydrogen is expected manufacturing technologies for the burning of
to increase by 7%. Thus, the demand currently being limestone for cement production, with 1 ton of cement
met within refineries by gray hydrogen can be replaced emitting an equal amount of CO2. 47
with green hydrogen (10% green hydrogen mandate) in
the initial stages. In addition, refineries that use fossil Cement is a mixture of limestone and clay and is one of
fuels instead of hydrogen can be mandated to use the the ingredients in concrete production along with
latter and shift to green hydrogen in the later stages. water, sand and gravel. To produce concrete, the
mixture is heated to a temperature of 1500oC.
Hydrogen can be used for such high temperatures and
4.8.1C CHEMICALS AND FERTILIZERS
to replace natural gas used in the production of cement.
The chemical sector is the largest industrial consumer
of oil and gas and ranks third in CO2 emissions, behind
cement, iron and steel46. Ammonia is one of the prime 4.8.2 FUEL FOR TRANSPORTATION
materials used in the production of synthetic nitrogen The transport sector is a major CO2 emitter,
fertilizers and India is the fourth-largest producer of contributing 25% to the global and 14% to national
nitrogenous fertilizers in the world. Conventionally, emissions caused by fuel combustion48. The Indian
ammonia is produced by mixing hydrogen (typically transport fuel mix is dominated by 96% oil %, followed
produced from fossil fuels) with atmospheric nitrogen, by 3% gas and 1% electricity. Diesel vehicles contribute
which is a highly CO2 intensive process. As ammonia is significantly (61%) to these emissions, followed by
not flammable, remains liquid at room temperature petrol vehicles (37%). Freight vehicles that use diesel
and is easy to transport, green ammonia can be used and passenger vehicles (two-wheelers and cars) are the
in lieu of hydrogen. This means hydrogen can be major segments that contribute to the emissions, given
converted to ammonia for transportation and then their large numbers49. Emissions from aviation and
reconverted to hydrogen at the destination. Although shipping too are increasing, with increase in air travel
this entails some energy loss, it presents a solution for and shipping becoming the backbone of global supply
the barriers in transporting and handling hydrogen. chains. Studies50 indicate that by 2050, the share of
Ammonia is also used in the production of nitrogenous low carbon fuel should increase to 60% in the
fertilizers, such as urea, ammonium sulphate, transport fuel mix to be compatible with the 1.5oC
ammonium sulphate nitrate, and ammonium chloride. limit.
Producing these from green hydrogen can help reduce
24
5.0 CONCLUSION technology, infrastructure, and capacity building,
both from the public as well as private sectors.
Essentially, this implies kick-starting the hydrogen
Reducing carbon emissions as well as the dependence economy by creating an enabling policy and regulatory
on fossil fuels are the foremost considerations that framework covering all aspects - production, safe
propel us towards hydrogen as a source of energy and storage, refuelling of stations, hydrogen-ready design
increasing its share in the country’s energy mix. There of transport vehicles, redesigning/reimagining
are multiple hydrogen production pathways and end-user applications to follow the hydrogen pathway
compelling economics for each category of hydrogen, and incentives for increasing the usage of hydrogen as
viz. blue, gray, and green. Hydrogen as an energy a fuel. A strategic alliance to unlock the potential
carrier can be used for a broad range of applications in synergies between the government and the private
different sectors and requires the setting up of suitable sector to address these aspects would help us meet
infrastructure. This calls for large investments in our climate goals.
1 kWh = 3.6 MJ
1 Btu = 1055.056 J
1 MMBtu = 293.07 kWh
39.4 kWh ( 1 kg of hydrogen ) = 0.1344 MMBtu
1 therm = 105.5056 MJ
1 calorie = 4.1868 J
1 tonne of oil equivalent (toe) = 41.868 GJ (LHV)
1 barrel of oil ≈ 5.70 GJ (IEA def.)
(LHV) 5.86 GJ (global avg.)
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