Targeting climate‐neutral hydrogen production: Integrating brown and blue pathways with green hydrogen infrastructure via a novel superstructure and simulation‐based life cycle optimization
Apoorv Lal, Fengqi You
Abstract
Abstract This article addresses the sustainable design of hydrogen (H 2 ) 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 H 2 . Moreover, the most environmentally friendly process attains net‐zero life cycle greenhouse gas emissions compared to 10.55 kg CO 2 ‐eq per kg H 2 for the most economically competitive process design.