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Processes
Special Issues
Sustainable Hydrogen Production Processes
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Sustainable Hydrogen Production Processes

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Chemical Processes and Systems".

Deadline for manuscript submissions: 30 June 2025 | Viewed by 4991

Special Issue Editors

Prof. Dr. Fausto Gallucci

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Guest Editor
Inorganic Membranes and Membrane Reactors, Sustainable Process Engineering, Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, 5612 AZ Eindhoven, The Netherlands
Interests: process design and intensification; membranes and membrane reactors; separation
Special Issues, Collections and Topics in MDPI journals
Dr. Orlando Palone

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Guest Editor Assistant
Department of Mechanical and Aerospace Engineering, La Sapienza University of Rome, 00185 Rome, Italy
Interests: chemical looping processes; CO2 capture, utilization and storage; hard-to-abate industries
Dr. Gabriele Gagliardi

E-Mail Website
Guest Editor Assistant
Department of Mechanical and Aerospace Engineering, Sapienza University of Rome, 00184 Rome, Italy
Interests: low-temperature fuel cells; composite membranes; green hydrogen production
Dr. Serena Agnolin

E-Mail Website
Guest Editor Assistant
Inorganic Membranes and Membrane Reactors, Sustainable Process Engineering, Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, De Rondom 70, 5612 AP Eindhoven, The Netherlands
Interests: material science; membrane separation; process intensification

Special Issue Information

Dear colleagues,

Hydrogen is being considered one of the most suitable energy carriers. However, to contribute to the decarbonization goals, hydrogen production must be sustainable. Sustainable hydrogen production can be attained via electrification (green hydrogen), as well as with innovative system-integrated carbon capture, with the decomposition of biomethane into C and hydrogen, and other novel systems.

This Special Issue seeks high-quality works focusing on the latest novel advances in hydrogen production and green hydrogen utilization. The topics of interest include, but are not limited to, the following:

  • Electrolysis;
  • Carbon capture for hydrogen production;
  • Novel technologies for sustainable hydrogen production;
  • Use of sustainable hydrogen, its storage and transportation.

Prof. Dr. Fausto Gallucci
Guest Editor

Dr. Orlando Palone
Dr. Gabriele Guglielmo Gagliardi
Dr. Serena Agnolin
Guest Editor Assistants

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • hydrogen production
  • green hydrogen
  • decarbonized hydrogen production
  • process intensification
  • catalysis
  • membranes
  • hydrogen conversion
  • hydrogen transport

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Published Papers (5 papers)

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Research

13 pages, 1244 KiB  
Article
Optimizing Hydrogen Production Through Efficient Organic Matter Oxidation Performed by Microbial Electrolysis Cells
by Angela Marchetti, Miriam Cerrillo Moreno, Roberto Lauri and Marco Zeppilli
Processes 2025, 13(4), 1231; https://doi.org/10.3390/pr13041231 - 18 Apr 2025
Viewed by 228
Abstract
Microbial electrolysis cells (MECs) represent a pioneering technology for sustainable hydrogen production by leveraging bioelectrochemical processes. This study investigates the performance of a single-chamber cathodic MEC, where a cation exchange membrane separates the electrically active bioanode from the cathode. The system was constantly [...] Read more.
Microbial electrolysis cells (MECs) represent a pioneering technology for sustainable hydrogen production by leveraging bioelectrochemical processes. This study investigates the performance of a single-chamber cathodic MEC, where a cation exchange membrane separates the electrically active bioanode from the cathode. The system was constantly fed with a synthetic carbonaceous solution, employing a working potential of +0.3 V vs. SHE and an organic loading rate of 2 gCOD/Ld with a hydraulic retention time of 0.3 d. Notably, no methanogenic activity was detected, likely due to the establishment of an alkaline pH in the cathodic chamber. Under these conditions, the system exhibited good performance, achieving a current density of approximately 115 A/m3 and a hydrogen production rate of 1.28 m3/m3d. The corresponding energy consumption for hydrogen production resulted in 6.32 kWh/Nm3 H2, resulting in a slightly higher energetic cost compared to conventional electrolysis; moreover, an average energy efficiency of 85% was reached during the steady-state condition. These results demonstrate the potential of MECs as an effective and sustainable approach for biohydrogen production by helping the development of greener energy solutions. Full article
(This article belongs to the Special Issue Sustainable Hydrogen Production Processes)
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22 pages, 10246 KiB  
Article
Techno-Economic Analysis of Sustainable Hydrogen Production from Offshore Wind Farms: Two Italian Study Cases
by Francesco Lanni, Laura Serri, Giovanni Manzini, Riccardo Travaglini, Francesco Superchi and Alessandro Bianchini
Processes 2025, 13(4), 1219; https://doi.org/10.3390/pr13041219 - 17 Apr 2025
Viewed by 241
Abstract
Renewable energy production is one of the pillars of the decarbonization process for the electricity system. The use of hydrogen can also contribute to the decarbonisation of industrial sectors such as chemicals, steel production, heavy industry, and long-distance transports. In Italy, a significant [...] Read more.
Renewable energy production is one of the pillars of the decarbonization process for the electricity system. The use of hydrogen can also contribute to the decarbonisation of industrial sectors such as chemicals, steel production, heavy industry, and long-distance transports. In Italy, a significant growth in wind and photovoltaic production is already foreseen by 2030. After that date, a wide deployment of offshore wind is expected with a significant decrease in cost. In a medium-long term scenario, with the massive expansion of renewable energy systems and the growing demand for hydrogen across multiple sectors, it is conceivable that some large-scale offshore wind farms (OWFs) could be exclusively dedicated to on-site green hydrogen production, thereby mitigating the impact on the electrical grid and simultaneously increasing hydrogen availability. This study reports the methods, assumptions, and results of a technical–economic analysis carried out for green hydrogen production from dedicated OWFs in two Italian offshore sites, one in Sicily and one in the Adriatic Sea. Despite the high uncertainty associated with carrying out this type of assessment for emerging technologies, the levelized costs obtained for dedicated offshore wind energy (approximately 70–80 EUR/MWh) and green hydrogen (approximately 5–6 EUR/kg) are in line with corresponding sector studies. Moreover, the simplified methodological approach developed is useful to analyse and compare other marine areas and different system configurations. Full article
(This article belongs to the Special Issue Sustainable Hydrogen Production Processes)
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26 pages, 3320 KiB  
Article
Techno-Economic Analysis of Hydrogen Transport via Truck Using Liquid Organic Hydrogen Carriers
by Carmine Cava, Gabriele Guglielmo Gagliardi, Enrica Piscolla and Domenico Borello
Processes 2025, 13(4), 1081; https://doi.org/10.3390/pr13041081 - 3 Apr 2025
Viewed by 356
Abstract
This study presents a techno-economic analysis of hydrogen transportation via liquid organic hydrogen carriers by road, comparing this option with compressed hydrogen (350 bar) and liquefied hydrogen. The analysis includes the simulation of hydrogenation and dehydrogenation reactors for the dibenzyltoluene/perhydro-dibenzyltoluene system using ASPEN [...] Read more.
This study presents a techno-economic analysis of hydrogen transportation via liquid organic hydrogen carriers by road, comparing this option with compressed hydrogen (350 bar) and liquefied hydrogen. The analysis includes the simulation of hydrogenation and dehydrogenation reactors for the dibenzyltoluene/perhydro-dibenzyltoluene system using ASPEN Plus, along with a cost assessment of compression, liquefaction, and trucking. A sensitivity analysis is also carried out, evaluating hydrogen transport at varying daily demand levels (1, 2, and 4 t/d) and transport distances (50, 150, and 300 km), with varying electricity prices and capital expenditures for hydrogenation and dehydrogenation units. Results indicate that compressed hydrogen is the most cost-effective solution for short distances up to 150 km, with a levelized cost of transported hydrogen ranging from 1.10 to 1.61 EUR/kg. However, LOHC technology becomes more competitive at longer distances, with LCOTH values between 1.49 and 1.90 EUR/kg at 300 km across all demand levels. Liquefied hydrogen remains the least competitive option, reaching costs up to 5.35 EUR/kg, although it requires fewer annual trips due to higher trailer capacity. Notably, at 150 km, LOHC transport becomes more cost-effective than compressed hydrogen when electricity prices exceed 0.22 EUR/kWh or when the capital costs for hydrogenation and dehydrogenation units are minimized. From an environmental perspective, switching from compressed to liquid hydrogen carriers significantly reduces CO2 emissions—by 56% for LOHCs and 78% for liquid hydrogen—highlighting the potential of these technologies to support the decarbonization of hydrogen logistics. Full article
(This article belongs to the Special Issue Sustainable Hydrogen Production Processes)
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21 pages, 1959 KiB  
Article
Energy Storage and Management of Offshore Wind-Based Green Hydrogen Production
by Isabella Pizzuti, Michela Conti, Giovanni Delibra, Alessandro Corsini and Alessio Castorrini
Processes 2025, 13(3), 643; https://doi.org/10.3390/pr13030643 - 24 Feb 2025
Viewed by 1153
Abstract
The coupling of offshore wind energy with hydrogen production involves complex energy flow dynamics and management challenges. This study explores the production of hydrogen through a PEM electrolyzer powered by offshore wind farms and Lithium-ion batteries. A digital twin is developed in Python [...] Read more.
The coupling of offshore wind energy with hydrogen production involves complex energy flow dynamics and management challenges. This study explores the production of hydrogen through a PEM electrolyzer powered by offshore wind farms and Lithium-ion batteries. A digital twin is developed in Python with the aim of supporting the sizing and carrying out a techno-economic analysis. A controller is designed to manage energy flows on an hourly basis. Three scenarios are analyzed by fixing the electrolyzer capacity to meet a steel plant’s hydrogen demand while exploring different wind farm configurations where the electrolyzer capacity represents 40%, 60%, and 80% of the wind farm. The layout is optimized to account for the turbine wake. Results reveal that when the electrolyzer capacity is 80% of the wind farm, a better energy balance is achieved, with 87.5% of the wind production consumed by the electrolyzer. In all scenarios, the energy stored is less than 5%, highlighting its limitation as a storage solution in this application. LCOE and LCOH differ minimally between scenarios. Saved emissions from wind power reach 268 ktonCO2/year while those from hydrogen production amount to 520 ktonCO2/year, underlying the importance of hydrogen in hard-to-abate sectors. Full article
(This article belongs to the Special Issue Sustainable Hydrogen Production Processes)
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20 pages, 3023 KiB  
Article
Hydrogen Network Synthesis Integrated with Multi-Stage and Multi-Technology Purification System
by Duankanghui Yang, Wenjin Zhou, Linlin Liu, Lei Zhang and Jian Du
Processes 2024, 12(11), 2415; https://doi.org/10.3390/pr12112415 - 1 Nov 2024
Cited by 1 | Viewed by 892
Abstract
Hydrogen, a vital resource, is utilized in many process units within the refinery. The purification system is widely used to regenerate and improve hydrogen quality, therefore reducing fresh hydrogen consumption. Pressure swing adsorption (PSA) and membrane separation (MS) technologies are widely utilized for [...] Read more.
Hydrogen, a vital resource, is utilized in many process units within the refinery. The purification system is widely used to regenerate and improve hydrogen quality, therefore reducing fresh hydrogen consumption. Pressure swing adsorption (PSA) and membrane separation (MS) technologies are widely utilized for the purification of hydrogen, and the process can be optimized by constructing mathematical models. Thus, at first, a parametric analysis of the purification models is conducted to identify the key variables of these models during the optimization process, which also reveals the necessity of coupling multiple purification units. Then, a superstructure-based hydrogen network (HN) model comprising multi-stage PSA and MS units is constructed, aiming to determine the optimal hydrogen allocation and purification system. This model considers the simultaneous optimization of purification system parameters, including operating pressure, in conjunction with its structural configuration. This case study demonstrates the applicability of the HN model to diverse refinery scenarios. Additionally, compared to using a single purification unit, using a multi-unit purification system can improve purification efficiency and reduce the total cost by 2% to 22%. Full article
(This article belongs to the Special Issue Sustainable Hydrogen Production Processes)
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