Why hydrogen Fuel?

Let us explore the key reasons behind using Hydrogen as a fuel in Transportation.

The global transport sector’s contribution to total CO2 emissions is close to 25%. Hence need to de-carbonize the transport sector as quickly as possible to arrest the global warming which is accelerating.

Decarbonizing transport refers to the process of reducing and eventually eliminating greenhouse gas emissions (GHG) associated with the transportation sector. This is crucial for combating climate change, as transportation is a major contributor to global CO2 and NOx emissions.

Hydrogen reacts or burns in air (with oxygen) releasing heat and water vapor only. This reaction highlights that no carbon containing products or CO/CO2 emissions at the point of use. No other green house gases (GHG). Here it is assumed complete burn or complete oxidation at normal temperature and pressure. Burning hydrogen at high pressure, high temperature in closed chamber results in production of NOx gases. However no CO/CO2 is produced.

Similarly when hydrogen is used in a fuel cell, hydrogen generates only electricity, water, and heat when it reacts with oxygen, through an electro chemical reaction. No carbon dioxide (CO2) or no other GH gas is produced when using hydrogen in a fuel cell because no combustion happens. Thus hydrogen as a clean fuel, no harm to environment, good for the climate to sustain. This makes hydrogen a very attractive option for transportation and power generation.

Hydrogen has highest gravimetric energy density (see the table) being the primary reason for considering hydrogen as a strong contender, as an alternative among all types of fuels. In simple terms, by weight, hydrogen holds a highest amount of energy. Approximately 3 kilograms of gasoline required to provide the same amount of energy as 1 kilogram of hydrogen. This physical aspect makes hydrogen as an energy carrier as well. This makes it extremely attractive for both transportation and stationary power applications.

Challenges:

Under normal pressure and temperature conditions, 1 kg of hydrogen occupies approximately 12,000 Litres where as 1 kg of gasoline = 1.34 Litres.

You can now imagine!

Due to its extremely low density, hydrogen in gaseous form takes up huge volume at normal atmospheric pressure. That is by volumetric energy density, hydrogen is the lowest among all. Hence for all practical purposes of hydrogen use, it has to be compressed or liquefied, this is the major roadblock in using hydrogen in transportation other than hydrogen is highly flammable and can ignite easily in normal conditions.

Hence in mobility applications like heavy duty, long haul transport, hydrogen storage requirements can significantly limit passenger and cargo space. Similarly, in passenger vehicles, there’s a trade-off between passenger space, comfort and range.

Reasons for considering Hydrogen as an alternative fuel, comparing with Battery electric vehicles (BEV):

It’s suitable for larger vehicles where battery weight could be prohibitive.

Heavy-duty transport is the ideal use case for hydrogen. The long-range capabilities and fast refueling mean they can match and exceed the performance of diesel trucks, while producing zero emissions at the tailpipe.

For long haul trucking, hydrogen provide a potential answer that could balance distance coverage, weight, and refueling duration. They have the capability to offer a range similar to that of diesel trucks and can be refueled less than 15 minutes. (using Liquid Hydrogen).

There are only two approaches for utilizing hydrogen fuel in transportation.

Hydrogen internal combustion engine (H2ICE or HICE):

This method involves burning hydrogen directly in an internal combustion engine, same like gasoline or diesel vehicles. This combustion generates power to drive the wheels. While emissions are cleaner, near zero CO2 than fossil fuel engines, they still produce NOx (nitrogen oxides), requiring additional exhaust control technologies. We must note that no CO/CO2 emissions are produced in the combustion of hydrogen directly in the engine (except some traces of CO2 from the burned lubricants). No solid particles are produced from the combustion exhaust.

The efficiency of H2ICE is approximately in the range of 38-40% inline with that of conventional gasoline, diesel counterparts.

Hydrogen engines are entirely mechanical, same like gasoline, diesel powered vehicles today.

Hydrogen Fuel Cell based Electric Vehicle (H2FC):

Here, hydrogen from onboard storage tank is converted back into electricity via a fuel cell onboard the vehicle. This generated electricity then powers the electric motor. However, due to energy losses during the conversion process (assuming green hydrogen is used), FCEVs require roughly 2.3 times more electricity to operate compared to battery electric vehicles. No mechanical or combustion process is involved as fuel cell, produces electricity through an electrochemical reaction.

Fuel cell based vehicles are pure zero emission vehicles (ZEV) as no CO2, NOx, unburnt fuels or solid particles are emitted, because there is no combustion or burning at all!

Onboard hydrogen storage challenges remains the same as that of H2ICE powered. There’s a trade-off between space and range.

Relative strengths of H2ICE and H2FC:

Heavy Commercial vehicles (HCV) of significant weight are often required to have extensive range and high-power capabilities. As such, HCVs, including long-haul trucks (LH), are prime candidates for hydrogen based. The hydrogen combustion engine (Hydrogen engines) presents a promising alternative to battery electric and fuel cell electric vehicles, contributing to the goal of a carbon dioxide-free commercial vehicle industry.

Potential Cost Advantage: H2ICE vehicles are cost-effective alternative to fuel cell vehicles, due to their simpler technology and adaptation of existing (gasoline) engine infrastructure.

H2ICEs could leverage the existing network of gas stations, thus easing the smooth transition to hydrogen fuel.

H2FC boast high efficiency (in terms of Fuel Tank Hydrogen to electricity), strictly zero emissions in par with a battery electric vehicle (BEV). However the cost is very high, and a very complex system, however intensive R&D is happening across to overcome the issues and huge cost associated.

.Hydrogen fuel in transportation is still in its infancy. However both H2FCV and H2ICE, have the potential to revolutionize the automotive industry by providing sustainable and eco-friendly transportation solutions.

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Hydrogen Blending: Introduction

Naturally available, raw natural gas is composed of primarily Methane of approximately 75 – 95% by volume.

The world’s natural gas (~ 90-95% Methane gas, further refined on raw natural gas) infrastructure has grown into a sprawling network over decades, has built vast networks spanning hundred thousands of kilometers, often referred to as transmission pipelines. They transport natural gas over long distances at high pressures (can vary depending on the pipeline) and large diameters (often exceeding one meter).

Methane is a much stronger greenhouse gas than carbon dioxide (CO2). Over a 20-year time frame, it traps over 72 to 80 times more heat than CO2. Dual contribution to global warming, firstly by burning natural gas, CO2 is released and other through leaks (from pipelines, agriculture, landfills) it reaches atmosphere directly.

Hence natural gas decarbonization is the second most priority after CO2 emission.

Leveraging existing infrastructure:

Hydrogen burns in clean way, only water vapor and heat released. No carbon based emissions. (small Nox is possible).

As hydrogen is playing a crucial role in the energy transition and decarbonization, it is natural to think why not use a low mixture of hydrogen and natural gas together towards the path of decarbonizing natural gas burning, by taking advantage of the vast pipelines of existing natural gas infrastructure.

Achieving carbon neutrality demands a shift from fossil fuels to clean alternatives. While transitioning directly to pure hydrogen might seem ideal, a more practical approach could involve an incremental blending of hydrogen with existing natural gas.

This blending strategy offers a seamless transition by leveraging existing infrastructure. By gradually increasing the hydrogen content (from 5% to final target < 40%), disruptions to public power and heating distribution networks can be minimized. This smoother path paves the way for a successful transition towards clean energy.

Here comes hydrogen blending!

Hydrogen blending is the controlled introduction of a specific proportion of hydrogen gas into an existing gas stream, typically natural gas. This creates a blended fuel with a lower carbon footprint compared to the original gas.

Mixing vs. Blending: Blending is a controlled and precise process, ensuring a consistent and well-defined hydrogen concentration within the final mixture. Mixing, on the other hand, can be less precise and might involve combining different gases without strict control over the final composition.

Infrastructure: Hydrogen blending leverages existing natural gas infrastructure like pipelines, compressor stations, and storage facilities. This significantly reduces the cost and time needed for widespread hydrogen adoption compared to building entirely new infrastructure for pure hydrogen.

Blending is primarily used for large-scale applications, such as decarbonizing the natural gas grid for power generation and industrial processes.

Main reason for adopting the blending:

• Approach for achieving near-term emissions reductions
• Early market access for hydrogen technologies
• Blending would primarily require minimal modifications to the existing fuel delivery infrastructure – pipeline networks
• Least or no changes to the appliances used by the consumers
• Experiment as one of the potential way to transport hydrogen over long distances without building new infrastructure
• No need for a huge substantial investment costs for creating dedicated hydrogen transmission and distribution infrastructure which is still in the early stages

Blending ratio:

Hydrogen embrittlement: It is well known that the presence of hydrogen causes cracking in commonly used pipeline solid metals and hydrogen also affects the fatigue properties of steels.Hence blend ratio depend on the design and condition of current pipeline materials, pipeline infrastructure equipment, and end user applications that utilize natural gas.

Learning and fine tuning the blending and outcome will open up new areas of using Hydrogen as a fuel with large blending ratio.

Most common blending of hydrogen with natural gas is 5% by volume.

For CNG vehicles, the current value for the proportion of hydrogen used is only 2 vol%, depending on the materials built in.

Range of Blending Ratios

Studies and trials suggest that blending up to 20% hydrogen by volume into natural gas pipelines might be technically feasible without requiring major infrastructure changes.

Researchers are studying how mixing hydrogen with methane (natural gas) affects the gas’s properties. This includes density, flow behavior (viscosity), how the gases mix (phase interactions), and the amount of energy it can hold (energy density).

• The goal is to understand if these blended fuels can be safely transported through pipelines and used in existing appliances like engines, burners, and fuel cells, potentially with some modifications.
• While hydrogen is a clean energy source, safety concerns exist when transporting the blended gas. These include potential for leaks and pressure build-up in pipelines.

Conclusion: Hydrogen Blending – Benefits, Ratio, effectiveness

Numerous challenges and uncertainties complicate blending approach to natural gas decarbonization.

The blending ratio of hydrogen in natural gas is currently a topic of research and development, with ongoing discussions about safety, infrastructure, and effectiveness. There isn’t a single universally accepted ratio.

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For decades, hydrogen has been touted as a potential game-changer in the clean energy transition. However, significant hurdles high cost, infrastructure, and production methods kept it grounded. But the winds are shifting. Driven by urgency for climate action, technological advancements, and very importantly government support, hydrogen is finally taking off.

The hydrogen industry actively adapts to a rapidly evolving regulatory environment, shifting global policies, geopolitical forces, new technologies, and ongoing leanings gleaned from project implementation.

In our constant pursuit of a fully de-carbonized world by 2050, the significance of hydrogen in transitioning to a net-zero state is increasingly getting clear.

Low-emission hydrogen production is poised to grow massively by 2030 despite cost challenges in deployment. The number of announced projects for low-emission hydrogen production is rapidly expanding as well hydrogen investments, market potential, projects globally.

The global hydrogen market is valued at USD 242.7 billion in 2023 and is projected to reach USD 410.6 billion by 2030. This projection indicates a compound annual growth rate (CAGR) of 7.8%.

Based on multiple sources, the current global pure hydrogen production (all types or all colors of H2) likely falls within the range of 75 to 95 million tonnes per year, with 3% increase on year on year. IRENA, places global production at around 75 MtH2/yr for pure hydrogen, with an additional 45 MtH2/yr as part of gas mixes [IRENA Hydrogen, 2022].

The global demand for hydrogen by 2030 is estimated to reach around 150 Mt (million metric tons) according to the International Energy Agency [2023 Hydrogen].

The clean hydrogen project pipeline is growing, with 1,418 projects announced across all regions (up from about 1,040 in the previous years), sums to USD 570 billion investments (previously USD 435 billion) and USD 39 billion (+26%) have passed FID (final investment decision).

45 million tons per annum (Mt p. a.) of clean hydrogen supply announced through 2030 (previously 38 Mt p. a.)

Of the total, 70% from renewable electrolysis and 30% from low carbon (fossil fuels with carbon capture, utilisation and storage (CCUS)

Electrolysis deployment globally has shown similar growth, already passing the 1 gigawatt (GW) mark in 2023 (up from 0.7 GW previously), with about 12 GW capacity having passed FID.

Europe shows the largest number of projects (540), followed by North America (248).

India shows the highest relative growth in investments of about 140%, corresponding to about 40 projects. The Middle East and China follow with about 80% and 50% growth in investments, respectively.

After a slow start, China has taken the lead on electrolyser deployment. In 2023, China’s installed electrolyser capacity was 1.2 GW – 50% of global capacity, with another new world record-size electrolysis project (260 MW), which started operation in 2023. The country accounts for more than 40% of the electrolysis projects that have reached FID globally in 2023 end.

All the data points by end of 2023.

Sources:

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A pioneering and a global force for Hydrogen: The Hydrogen Council

The Hydrogen Council stands out as a truly groundbreaking initiative. Launched in 2017 at the World Economic Forum in Davos, it was, and remains, the first of its kind globally.

Initially formed by 13 leaders from the energy, transportation, and manufacturing sectors, the Council has grown significantly in its six years. Today, it boasts nearly 150 multinational companies based in 20+ countries, encompassing the entire hydrogen value chain.

The story began with a shared vision: limiting global warming to 2°C, following the ambitious target set by the 2015 Paris Agreement. These 13 founding members – renowned global companies like Air Liquide, Toyota, and Shell – came together to create the Hydrogen Council and champion the use of hydrogen as a key driver of the energy transition. Dually led by Co-Chairs from different regions and sectors (initially Air Liquide and Toyota, currently Kawasaki and Linde), the Council fosters collaboration and innovation to unlock the full potential of hydrogen.

Here are some key takeaways from their website:

• Focus on Sustainability: The council promotes hydrogen as a way to achieve clean energy goals and reduce reliance on fossil fuels.
• Collaboration: They bring together industry leaders, governments, investors, and civil society to collaborate on hydrogen solutions.
• Promoting Hydrogen Ecosystems: Their work involves advocating for policies, safety standards, and infrastructure development to support widespread hydrogen use.
• Industry Leadership: The council is a significant player in the hydrogen space, with member companies representing diverse aspects of the hydrogen value chain – from production to applications.
• Insights and Resources: They offer reports, updates, and information on the global hydrogen economy, providing valuable insights for stakeholders interested in this technology.

Overall, the Hydrogen Council acts as a catalyst for the hydrogen industry, aiming to make hydrogen a mainstream clean energy solution.

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