TARGETING CLIMATE-NEUTRAL HYDROGEN PRODUCTION: INTEGRATING BROWN AND BLUE PATHWAYS WITH GREEN HYDROGEN INFRASTRUCTURE VIA A NOVEL SUPERSTRUCTURE AND SIMULATION-BASED LIFE CYCLE OPTIMIZATION
This work 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. In this work, we estimate the optimal unit-levelized cost of hydrogen per kg H2 for different hydrogen production pathways. The most environmentally friendly process attains net-zero life cycle greenhouse gas emissions, albeit at a significantly higher levelized cost compared to the most economically competitive process design, which results in substantially increased emissions.