Study, cost, and system analysis of liquid hydrogen production Final report
Study, cost, and systems analysis of present and projected liquid hydrogen production
Hallett, N. C.↗
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Liquid hydrogen production and commercial demand in the United States
Kennedy Space Center, the single largest purchaser of liquid hydrogen (LH2) in the United States, evaluated current and anticipated hydrogen production and consumption in the government and commercial sectors. Specific objectives of the study are as follows: (1) identify LH2 producers in the United States and Canada during 1980-1989 period; (2) compile information in expected changes in LH2 production capabilities over the 1990-2000 period; (3) describe how hydrogen is used in each consuming industry and estimate U.S. LH2 consumption for the chemicals, metals, electronics, fats and oil, and glass industries, and report data on a regional basis; (4) estimate historical and future consumption; and (5) assess the influence of international demands on U.S. plants.
Heydorn, Barbara↗
Plan for Scaling Up Hydrogen Production with Nuclear Power Plants
The United States (U.S.) Department of Energy’s (DOE’s) Light Water Reactor Sustainability (LWRS) Program Flexible Plant Operations and Generation (FPOG) Pathway is developing options to help U.S. nuclear power plants (NPPs) better integrate with intermittent wind and solar capacity and the recent surge of natural gas power generation. Research is focusing on improving NPP flexibility through hybrid production of electricity and other products, such as hydrogen (H 2 ) and energy storage for the purpose of shifting power production to a later time. In the case of H 2 production, the clean electrical and thermal power from an NPP can be used to split water using electrolysis. This report outlines the opportunity for NPPs to participate in a first-of-akind (FOAK) commercial nuclear H 2 project intended to bring industry partners together to create regional clean H 2 hubs. The Bipartisan Infrastructure Law (BIL) will fund at least one hub up to $1.25 billion as federal cost share totally no less than 50% to execute a nuclear H 2 project. The report discusses the set of activities that are now underway or that are planned for completion by the FPOG Pathway to reduce the economic, technical, regulatory, and safety risks of these projects. DOE cross-program activities are being coordinated to ensure success in the timeframe allowed by the BIL. Figure ES-1 shows the approximate schedule of coordinated research and development (R&D) and pilot demonstration projects leading up to the first commercial nuclear H 2 production project. Execution of this plan requires DOE and industry collaboration. DOE research accomplishments are being provided to the electric utilities or industries looking to participate in the H 2 hub proposal and project execution process.
08 HYDROGEN↗
Life Cycle Analysis of Hydrogen Production via Plasma Pyrolysis of Natural Gas: Impact of Different Co-Product Management Strategies
The slides provide an overview of the attributional LCA analysis of hydrogen production via plasma pyrolysis of natural gas. Topics include Project Background and Motivation LCA Methodology, including specifics related to co-product management schemes LCA Results Discussion
hydrogen↗
Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies
Presentation describing NETL's public report entitled "Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies" which features levelized cost of hydrogen (LCOH) and greenhouse gas emissions from six cases (3 reforming and 3 gasification technology cases) as well as CO2 capture. One case also features coal/biomass co-gasification that targeted net-zero emissions.
Stevens, Robert↗
Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies
This report presents an independent assessment of the cost and performance of select hydrogen production plants utilizing fossil fuel resources as the primary feedstocks – specifically, natural gas (NG), steam methane reforming (SMR), NG autothermal reforming (ATR), coal gasification, and coal/biomass co-gasification – using a systematic, transparent technical and economic approach. Study cases were selected to reflect the capabilities of current, commercial technologies within plant configurations, and at scales, representative of next commercial offerings facing no fundamental research and development (R&D) obstacles. Additionally, several areas of R&D are identified as potential pathways for performance improvements and cost reductions.
08 HYDROGEN↗
Novel dense-PBI membranes for photoelectrochemical hydrogen production
Summary and main accomplishments 1. Screening of available polybenzimidazole (PBI) membranes for photoelectrochemical (PEC) hydrogen production. 2. Two main candidate membranes selected and synthesized. 3. Selected membranes characterized, including assessment of electrochemical properties (conductivity) and mechanical properties (creep and creep compliance). 4. Single cell PEC system successfully fabricated. 5. Electrochemical cell tested with initial water decomposition results obtained under ‘dark electrolysis’ conditions. 6. Recommendations given for future test and work.
Corgnale, Claudio [Greenway Energy; Greenway Energ↗
Accelerated Discovery of Solar Thermochemical Hydrogen Production Materials via High-Throughput Computational and Experimental Methods
In this project, combinatorial synthesis and testing methods were combined with high-throughput materials theory calculations to greatly accelerate the discovery of thermodynamically suitable candidates for green hydrogen production via a two-stage solar thermochemical water splitting (STCH) process. Over the course of the project, more than 8000 quinary and higher oxide compositions were computationally screened for STCH viability, and detailed stability calculations were performed for more than 30 of the most promising identified compositional archetypes. As a result, three new STCH capable compositional families were discovered and experimentally verified. The first, Ce x Sr 2-x MnO 4 (CSM), represents the first known Ruddlesden-Popper compound to show STCH activity, and thus demonstrates that perovskite-related structures may hold promise for this application. The second family, Sr 1-x Ce x MnO 3 (SCM), is the simple perovskite sister-analog to CSM. Sr 0.7 Ce 0.3 MnO 3 (SCM30), a member of this compositional family, was found to produce the highest hydrogen yields of any compound tested in this project, exceeding the end of project milestone target of > 150 μmol H 2 /gram oxide at a reduction temperature of 1350 °C, although only at steam-to-hydrogen ratios greater than 1000:1. Finally, we proved that a third novel Sr-and Mn-containing family, Sr 1-x Ca x Ti 1-y Mn y O 3 (SCTM), which was identified by Materials Project tools, also splits water. The behavior of the SCTM system was found to be similar to the previously discovered Sr 1-x La x Al 1-y Mn y O 3 (SLMA) family, albeit with lower H 2 yields. Across the three thrusts of the project (computational, combinatorial, and bulk testing), five journal articles were published. As part of Program End Analysis and Data Dissemination, relevant data used for the publications was uploaded to the HydroGEN Data Hub for public access, and in certain cases, results were added to public materials databases.
08 HYDROGEN↗
Atomic hydrogen production rates for comet P/Halley from observations with Dynamics Explorer I
Newly analyzed observations of the Dynamics Explorer I (DE1), launched on August 3, 1981, were used to determine the hydrogen production rate for Comet Halley at heliocentric distances, r, less than about 1.5 AU from measurements of the total Lyman-alpha flux at earth due to the cometary neutral hydrogen distribution. The production rates, determined as a function of r, were found to be consistent with in situ measurements from the Giotto and Vega spacecraft. The calculated rates are also consistent with remote observations using two sounding rockets and with the Pioneer-Venus and IUE spacecraft.
Craven, J. D.↗
Computationally Accelerated Discovery and Experimental Demonstration of High-Performance Materials for Advanced Solar Thermochemical Hydrogen Production
This project achieved its overarching goal of accelerating the discovery and validation of solar thermochemical hydrogen (STCH) materials through a tightly integrated approach that combined high-throughput computational screening, advanced machine learning (ML), and experimental testing. Guided by the objectives outlined in the Statement of Project Objectives (SOPO), our work fulfilled all major milestones across four technical tasks and delivered scientific breakthroughs and practical tools that significantly exceeded the original scope of the project. We began by addressing the challenge of predicting material phase stability through machine learning. A novel Python module was developed to generate thousands of meaningful features from composition, structure, and electronic properties, enabling rapid and reproducible ML model development. Using these tools, we trained a model to predict temperature-dependent Gibbs energies (G(T)) for inorganic crystalline materials with near-chemical accuracy—roughly 40 meV/atom—marking the first such descriptor of its kind. We also introduced a new machine-learned tolerance factor, τ, that accurately predicted perovskite formability with over 90% success, outperforming traditional heuristic models, such as the Goldschmidt tolerance factor. These capabilities allowed for rapid and accurate predictions of phase stability across a vast oxide composition space, setting the stage for high-throughput thermodynamic screening. Building on this foundation, we conducted an extensive computational screening of candidate STCH oxide materials. Over 1.1 million perovskite compositions were evaluated using the τ descriptor, leading to the identification of more than 27,000 predicted stable structures. Using density functional theory (DFT), we refined over 68,000 multinary perovskite structures and computed oxygen vacancy formation energies for over 1,300 ternary and double perovskites. These calculations enabled us to isolate compounds with redox behavior consistent with STCH requirements and resulted in a public dataset now hosted on the Materials Project. Recognizing that thermodynamic screening alone is insufficient, we addressed kinetic limitations by developing a suite of tools to estimate transition state (TS) energies for key redox reactions. We implemented a novel bounding approach that provides lower and upper estimates of TS energies with dramatically reduced computational cost, requiring less than 10% of the CPU time of a full nudged elastic band (NEB) calculation while maintaining high accuracy. This enabled rapid evaluation of over 200 reaction pathways across 90 materials. To further accelerate screening, we developed a SISSO-based ML model to predict diffusion barriers with a 96.7% success rate in classifying fast vs. slow materials, supporting a robust, data-driven framework for assessing redox kinetics. Experimental validation was critical to confirming the predictive power of our models. We synthesized and tested a wide array of candidate materials, including Mn-doped hercynite and several Gd- and La-based perovskites. Notably, Sr 0.4 Gd 0.6 Mn 0.6 Al 0.4 O 3 (SGMA) and Gd 0.5 La 0.5 Co 0.5 Fe 0.5 O 3 (GLCF) emerged as leading STCH materials, exhibiting robust redox cycling and high hydrogen yields exceeding 150 µmol H 2 /g per cycle. These materials also retained over 50% of their hydrogen productivity under high-conversion conditions (H 2 O:H 2 = 1333:1), demonstrating strong thermodynamic favorability and promising performance under industrially relevant scenarios. Additional candidates, such as La 2 MnNiO 6 (L2MN), were found to produce even higher yields than ceria under standard STCH conditions. Our collaborators at Sandia National Laboratories confirmed these findings using high-temperature X-ray diffraction and thermogravimetric analysis, observing stable phase evolution and reversible redox activity. In several respects, the project went beyond the goals initially outlined in the SOPO. We published 17 peer-reviewed articles, including a large dataset of over 66,000 theoretical perovskites and a new structure prediction method (SPuDS-DFT) that accurately identifies ground-state structures at a fraction of the cost of traditional DFT. We demonstrated that our machine-learned G(T) model offers accuracy rivaling quasiharmonic calculations while being orders of magnitude faster. In partnership with the Materials Project, we made our datasets openly available, providing a powerful new resource for the broader materials science community. The combined computational and experimental advances of this project represent a significant advance in STCH materials discovery. By creating a robust, generalizable, and open workflow for thermodynamic and kinetic screening, and validating key findings through synthesis and reactor testing, we have provided a practical and scalable pathway for the rapid identification of new redox-active materials. The tools, data, and materials developed under this project are already supporting ongoing research and have laid the groundwork for the next generation of solar fuel technologies.
08 HYDROGEN↗
Is Clean Hydrogen Production a Good Fit for Questa? Intermediate Feasibility Study Results
NREL conducted a feasibility study for a clean hydrogen production facility that would be located in Questa, New Mexico. This slide deck presents the history of the coalition of stakeholders that received NREL technical assistance through the Department of Energy's Communities Leading Energy Action Program. It describes how hydrogen is generated and its end uses. It describes two conceptual applications explored in the feasibility analysis, a grid-tied power generation and long-term storage application and a heavy-duty vehicle fueling application. The presentation details the configuration of these to applications in the Questa pilot facility, including system components, required inputs (water, electricity, and land for pv generation), and outputs in kilograms of hydrogen, megawatt hours of power delivered, and hours of vehicle hours of operation. The presentation addresses key concerns raised by groups engaged through a public outreach process, including safety, health, and environmental issues; water use; visual impacts; and costs and alternatives.
heavy-duty vehicle fueling↗
Atomically Fine-Tuning Organic–Inorganic Carbon Molecular Sieve Membranes for Hydrogen Production
Polymeric membranes with great processability are attractive for the H 2 /CO 2 separation required for hydrogen production from renewable biomass with carbon capture for utilization and sequestration. However, it remains elusive to engineer polymer architectures to obtain desired sub-3.3 Å ultramicropores to efficiently sieve H 2 from CO 2 . Herein, we demonstrate a scalable way of carbonizing polybenzimidazole (PBI) at low temperatures, followed by vapor phase infiltration (VPI) to atomically narrow ultramicropores throughout the films, forming hybrid organic–inorganic carbon molecular sieves (CMSs). One VPI cycle (100 s) for the PBI carbonized at 500 °C remarkably increases H 2 /CO 2 selectivity from 9.6 to 83 at 100 °C, surpassing Robeson’s upper bound. The CMS demonstrates a stable H 2 /CO 2 separation performance when challenged with simulated syngas streams and can be fabricated into thin-film composite membranes, outperforming state-of-the-art membranes. Finally, the scalable approach can be ubiquitous to molecularly fine-tune ultramicropores of leading polymeric membranes to further improve their size-sieving ability and thus separation efficiency.
36 MATERIALS SCIENCE↗
Slush hydrogen production, storage, and distribution study program Final report, 4 Nov. 1965 - 29 Apr. 1966
Production of slush hydrogen for nuclear rocket propulsion testing
SLUSH↗
Developing novel electrodes with ultralow catalyst loading for high-efficiency hydrogen production in proton exchange membrane electrolyzer cells
Hydrogen plays more crucial roles for decarbonizing the planets and meeting the climate challenges because of its high energy density and zero-emission. It can be produced with proton exchange membrane electrolyzer cells (PEMECs) driven by sustainable and renewable energy resources. Although PEMECs have a number of advantages, including high purity production, quick response, and the ability to operate at high pressure facilitating the gas delivering, their performance and cost greatly hinder their commercial-scale applications. To achieve high-efficiency and cost-reduced hydrogen production in PEMECs, we proposed thin engineered liquid/gas diffusion layers (LGDLs) and associated electrodes, i.e., catalyst-coated LGDLs (CCLGDLs), over conventional porous transport layers (PTLs) and catalyst-coated membranes (CCMs). The research approaches in this project are based on material synthesis, in-situ and ex-situ characterizations, component design and treatment, numerical modeling, and cost analysis. The thin and tunable LGDLs (TT-LGDLs) and CCLGDLs were successfully developed with great performance improvement as demonstrated in lab-scale, bench-scale, and system-scale electrolyzer tests. The electrode thickness was reduced from 370 µm to less than 100 µm with simplified fabrication processes. With the catalytically enhanced Ir-based catalyst coating, the as-developed CCLGDLs with a catalyst loading of 0.34 mg Ir /cm 2 achieved a cell performance of 1.77 V at 2 A cm -2 , exhibiting the catalyst mass activity enhanced by >20 times with significant catalyst saving over conventional catalyst cell design. In-situ PEMEC characterizations, including the current distribution mapping and high-speed and multiscale visualizations, were conducted for a deeper understanding of mass transport and electrochemical reactions within an electrolyzer with LGDLs and CCLGDLs. A 2D cell model was developed and validated for the enhanced performance on TT-LGDL through reducing ohmic losses due to nonuniform hydration and water transport. Further, the cost analysis results have shown a path to move beyond equivalency and surpass costs associated with the project baseline. In this project, the design and fabrication of TT-LGDLs and CCLGDLs will contribute to the performance enhancement, manufacturing simplification, and cost reduction for PEMECs and other energy conversion devices, thus shortening their pathways towards commercialization. This project also provides a good foundation for furthering the in-situ reaction interface research.
08 HYDROGEN↗
Evidence of redox cycling as a sub-mechanism in hydrogen production during ethanol steam reforming over La 0.7 Sr 0.3 MnO 3-x perovskite oxide catalysts
Ethanol steam reforming (ESR) is of societal interest. Here, in this work, experiments were conducted to ascertain if some of the H 2 is produced by a redox cycle involving H 2 O filling oxygen vacancies over reducible oxide catalysts. Redox cycling experiments were performed over La 0.7 Sr 0.3 MnO 3-x (100) in ultra-high vacuum. It was found that H 2 was produced from redox cycling with alternating ethanol and water exposures over La 0.7 Sr 0.3 MnO 3-x (100), with both half-cycles occurring at temperatures ≤800 K. In the first half-cycle, ethanol ‘directly’ reduced the surface to create oxygen vacancies (not by a CO intermediate), and in the second half-cycle water filled oxygen vacancies to make H 2 . The H 2 production during the water exposure has a half-cycle turnover frequency of >3.2 × 10 -2 molecules site -1 s -1 in the temperature range of 700–800 K, which is fast enough to be part of the ESR full catalytic cycle. Flowing both reactant gases together, ethanol and water, over La 0.7 Sr 0.3 MnO 3-x (100) and La 0.7 Sr 0.3 MnO 3-x powders significantly increases hydrogen production compared to pure ethanol. The results suggest that steady state ESR includes a sub-mechanism of ethanol ‘directly’ reducing the surface to create oxygen vacancy, and water filling oxygen vacancy to make some of the H 2 by a Mars van Krevelen type mechanism.
08 HYDROGEN↗
Clean Hydrogen Production R&D
Comprehensive, concerted efforts supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO) are advancing research and development to demonstrate clean hydrogen production and industrial decarbonization pathways. These pathways enable an economically competitive and environmentally beneficial future energy system across sectors and can address specific applications that are difficult to decarbonize. NREL's research accelerates development, integration, and scale up of hydrogen and fuel cell technologies to enable widespread deployment across multiple energy sectors. Our work helps industry overcome technical challenges and supports DOE's H2@Scale vision for clean hydrogen across multiple applications and economic sectors. We also bridge technologies with other research areas across the lab and through multiple DOE and national lab research initiatives, consortia, and collaborations including: H2NEW: Hydrogen from Next-generation Electrolyzers of Water Consortium, HydroGEN: Advanced Water Splitting Materials Consortium, and BioH2. Within the plenary panel called: From the Classroom to the Lab to the Board Room, I will represent the Lab in this panel and will be talking about hydrogen technology at NREL, the lab's role in bridging university research with industry commercialization. I will also talk about my personal career path and what it's like to work at NREL, along with work force development and DEIA programs at NREL.
BIL↗
A Thermogravimetric Temperature-Programmed Thermal Redox Protocol for Rapid Screening of Metal Oxides for Solar Thermochemical Hydrogen Production
As combinatorial and computational methods accelerate the identification of potentially suitable thermochemically-active oxides for use in solar thermochemical hydrogen production (STCH), the onus shifts to quickly evaluating predicted performance. Traditionally, this has required an experimental setup capable of directly carrying out a two-stage thermochemical water-splitting process. But this can be a difficult endeavor, as most off-the-shelf equipment cannot adequately deal simultaneously with the high temperatures, varying oxygen partial pressures, and high H 2 O partial pressures required; achieving sufficient temporal sensitivity to accurately quantify the kinetics is also a major challenge. However, as proposed here, a less complicated experiment can be used as a first screening for thermochemical water splitting potential. Temperature-Programmed Thermal Redox (TPTR) using thermogravimetry evaluates the thermal reduction behavior of materials. This technique does not require water splitting or CO 2 -splitting analogs but can nonetheless predict water-splitting performance. Three figures of merit are obtained from the TPTR experiment: reduction onset temperature, extent of reduction, and extent of recovery upon reoxidation. These metrics can collectively be used to determine if a material is capable of thermochemical water-splitting, and, to good approximation, predict whether the thermodynamics are favorable for use under more challenging high-conversion conditions. This paper discusses the pros and cons of using TPTR and proposes a protocol for use within the STCH community.
08 HYDROGEN↗
Techno-Economic Analysis of Hydrogen Production and Compressed Air Energy Storage from Variable Renewable Energy
Examines the performance and cost of pairing variable renewable energy (VRE) sources with compressed air energy storage and hydrogen production through PEM electrolysis. Sensitivities were performed on H2 cost, PEM electrolyzer capital cost, and hydrogen cavern capital cost. The analysis shows that the cost of VRE has the most impact on the overall cost results.
Teel, Troy↗