The goal of this assessment is to quantify the impact of hydrogen's indirect climate effects and leakage rates on the life cycle emissions of different hydrogen production methods and end uses. We use a life cycle assessment (LCA) model constructed through the Open LCA software and the IPCC 2021 impact assessment method to estimate greenhouse gas emissions intensity of various hydrogen production pathways [26]. The functional unit is the product of concern, which in this case is hydrogen or the concerned end use (highlighted in red in the data tables). Every phase of the life cycle is divided into processes, which are subsequently interconnected through intermediate flows, thereby forming a product system. The data used to conduct this analysis was obtained from the Ecoinvent database [27], a sustainability assessment life cycle inventory, in addition to available hydrogen leakage rates obtained from a study conducted by Esquivel-Elizondo S., et al [17]. The GWP100, and GWP20 of hydrogen obtained from a study conducted by Hauglustaine., et al [19] reported in Table 1 were incorporated in the assessment. These values were used in order to understand the warming potential of each production pathway with associated leakage and indirect hydrogen climate impact over time.
Table 1
GWP values for hydrogen from Hauglustaine., et al [19] in this table were added to the IPCC 2021 impact assessment method and used in this study.
Climate Change Metric | Value |
GWP100 | 13 |
GWP20 | 40 |
Production:
The production methods taken into consideration in this analysis are unabated SMR (SMR without CCS), SMR coupled with 96% CCS, electrolysis using a grid mix supply of electricity, electrolysis using solar (equivalent kWh not hourly matched), and electrolysis using wind energy (equivalent kWh not hourly matched). Figures 5, 6, and 7 display the system boundaries of the production methods used. The system boundary for the SMR pathways begins with the raw material production and transport of natural gas, deionized water, metallurgical aluminum oxide, magnesium oxide, copper oxide, quicklime, chromium oxide, zinc oxide, zeolite powder, molybdenum trioxide, silica sand, and portafer. Additionally, the embedded emissions of the chemical factory and storage tank are included. The natural gas is sourced from markets in the United States (U.S.), and the remaining inputs are sourced from the global market. The system boundary for the electrolysis pathways begins with deionized water, the designated electricity supplier (grid, solar, wind, or renewable mix) and their capital expenditure (CAPEX) emissions. The electricity for electrolysis is sourced from the Texas Regional Entity (TRE) for grid mix and wind electrolysis and from the Western Electricity Coordinating Council (WECC) for solar (photovoltaic) electrolysis. For all the production processes, the system boundaries stop after the production of hydrogen (that is, at the system gate). Tables 2–5 detail the inputs and outputs of each production process considered in this study.
Table 2
Input parameters for SMR and SMR + CCS production pathways with corresponding units. Oxides: Aluminum oxide, Chromium oxide, Copper oxide, Magnesium oxide, Molybdenum trioxide, Zinc oxide. Natural gas, water oxides, nickel, portafer, quisklime, silica, and zeolite powder data sourced from Ecoinvent. Electricity input for CCS was obtained from NETL [28].
Input Parameters | Values | Units/kgH2 |
Natural Gas | 4.6 | m3 |
Water (cooling) | 0.4 | m3 |
Deionized water | 4.4 | kg |
Oxides | 1.40E-03 | kg |
Nickel | 2.00E-04 | kg |
Portafer | 3.00E-04 | kg |
Quicklime | 4.80E-05 | kg |
Silica | 1.20E-05 | kg |
Zeolite powder | 9.00E-04 | kg |
Electricity (CCS only) | 1.15 | kWh |
Table 3: Output parameters for SMR and SMR+CCS production pathways with corresponding units. Hydrogen leakage data is detailed in Table 7. The remaining data is sourced from Ecoinvent. The hydrogen leakage is emitted to the atmosphere. Stack emissions include acetaldehyde, acetic acid, benzene, benzoapyrene, butane, carbon dioxide, carbon monoxide, dinitrogen monoxide, formaldehyde, mercury, methane, nitrogen oxides, polycyclic aromatic hydrocarbons (PAH), particulate matter, pentane, propane, propionic oxide, sulfur dioxide, and toluene.
Output Parameters
|
Values
|
Units
|
Stack emissions
|
5.7E-04
|
kg
|
Hydrogen
|
1
|
kg
|
Carbon dioxide
|
9
|
kg
|
Carbon dioxide (with CCS)
|
0.34
|
kg
|
Hydrogen Leakage
|
varies
|
kg
|
Table 4
Input parameters for electrolysis production pathways with corresponding units. The electricity input is obtained from the National Energy Technology Laboratory [29] and the deionized water input is obtained from WaterSMART Ltd [30].
Input Parameters | Values | Units |
Electricity | 40 | kWh |
Deionized water | 9 | kg |
Table 5: Output parameters for electrolysis production pathways with corresponding units.
Output Parameters
|
Values
|
Units
|
Hydrogen
|
1
|
kg
|
Hydrogen Leakage
|
varies
|
kg
|
The data for the SMR production processes (Tables 2 and 3) are based on an SMR plant assessed by Antonini., et al. [31]. The natural gas is pressurized at 200 bars. The hydrogen yield of the process is enhanced with a water gas shift reaction. In the unabated SMR process, the carbon dioxide exits the plant with the flue gas from the furnace. A separate model for CCS was not built for this LCA, rather a 96.2% capture rate was applied to the total amount of carbon dioxide emitted from the base unabated SMR process, and the subsequent electricity requirements were added as additional input. The electricity input value calculations were based on findings from the National Energy Technology Laboratory [28]. The electricity and water input values for electrolysis were obtained from reports published by the National Renewable Energy Laboratory [29, 32, 33]. This analysis does not take into account specific variations between PEM and alkaline electrolyzers, as the differences are small.
An upper limit, lower limit, and average leakage rates were assessed for each production method to gauge the sensitivity of supply chain greenhouse gas emissions intensity to leakage rates. These leakage rates are detailed in Table 6. An assessment of current reported hydrogen leakage rate projections for 2050 by Esquivel-Elizondo S., et al [17], revealed considerable variation. Electrolysis with renewables has the highest reported leakage rates varying between 2.0% (lower limit) and 9.2% (upper limit). These relatively high values are due to venting and purging that occur for safety reasons as a result of oxygen build up during the electrolysis process. Unabated SMR and SMR with CCS have leakage rates that vary between 0.5% and 1.0%. There are limitations in the leakage values used as they are obtained from simulations or models. There is little to no direct measurement data available on hydrogen leakage. Methane leakage during the SMR processes is < 1% (default in the Ecoinvent database).
Table 6
Hydrogen leakage rates used for the sensitivity analysis. Data obtained from Esquivel-Elizondo S. et al. [17]. Average value represents value calculated for taking the average of 2050 leakage rate predictions.
| Leakage rate | Percentage (%) |
SMR | Upper limit | 1 |
Average | 0.8 |
Lower limit | 0.5 |
SMR + CCS | Upper limit | 1.5 |
Average | 0.8 |
Lower limit | 0.6 |
Electrolysis | Upper limit | 9.2 |
Average | 4.6 |
Lower limit | 2 |
Production Model Validation:
A validation was conducted by comparing the results from the models in this study to the Hydrogen Production Emissions Calculator (HyPEC) tool version 1.0, which is based on the GREET model version 2021 [34, 35]. Figure 8 shows the results of this validation, excluding the indirect warming effect of hydrogen. At the time of this analysis, the 45V-GREET had yet to be made available. The difference between the models for all the production pathways considered is less than 2 kgCO2e / kgH2. In both models, upstream methane emissions are less than 1%.
Steel Case and Heavy-Duty Transport Case Studies:
The steel and heavy-duty transport pathways selected are based in Texas to mimic future scenarios as one of the DOE hydrogen hubs, Gulf Coast Hydrogen Hub (HyVelocity), is expected to be constructed in Houston. A hydrogen pipeline transportation distance of 400km is assumed with the scenario that the hydrogen would be produced in Houston and used at some location within or on the outskirts of the Texas Triangle. The Texas triangle is defined as the area encompassing Austin, Dallas-Fort Worth, Houston, and San Antonio with the latter three as the corners connected by Interstate 45, Interstate 10, and Interstate 35. The distance chosen for pipeline transport represents the average of the three sides of the Texas triangle rounded up to the nearest hundred. The percentages of hydrogen leaked during pipeline transport and end use consumption used in the model are specified in Table 7. An average leakage rate of 0.3% is assumed during hydrogen pipeline transport [17]. Tables 8 and 9 detail the input and outputs of these end uses, and Figs. 9, and 10 illustrate the system boundaries for the end uses applied in the two supply chains. The gas power plant stack emissions in the electricity supply chain include acenaphthene, acetaldehyde, acetic acid, arsenic ion, benzene, benzo(a)pyrene, beryllium II, butane, cadmium II, carbon monoxide, chromium III, cobalt II. dinitrogen monoxide, dioxins measured as 2,3,7,8-tetrachlorodibenzo-p-dioxin, ethane, formaldehyde, hexane, lead II, manganese II, mercury II, methane, nickel II, nitrogen oxides, PAH, particulate matter, pentane, propane, propionic acid, selenium IV, sulfur dioxide, and toluene [27]. Hydrogen fuel cell trucks have varying characteristics such as on-board hydrogen storage, battery size, fuel cell power, and range which present difficulties in systems level modeling for hydrogen based heavy-duty trucking. For example, the Xcient fuel cell truck with range of 400 km developed by Hyundai has a 72-kWh battery, 190 kW fuel cell power, and can carry 31 kg of hydrogen compressed at 350 bars. The Daimler truck, which was developed by Mercedes Benz and has a range of 1000 km, demonstrated the use of liquid hydrogen (80 kg maximum capacity) with 70 kWh battery size and 300 kW fuel cell power [25]. Consequently, this study only assesses the necessary hydrogen input for transporting 1 tonne over a km obtained with the characteristics of Xcient fuel cell truck.
Table 7
Supply chain hydrogen leakage rates used in the assessment. Data obtained from Esquivel-Elizondo S., et al [17].
| Percentage |
Pipeline | 0.30% |
Steel | 0.36% |
Heavy Duty Transport | 1.60% |
Table 8
Inputs for the supply chain end uses assessed in this study and corresponding units. All upstream processes are auto linked by open LCA.
| Input Parameters | Values | Units/kgH2 |
Steel Manufacturing | Hydrogen | 50 | kg |
Iron ore concentrate | 1.6 | tonne |
Limestone | 0.2 | tonne |
Water | 58 | m3 |
Electricity (grid mix) | 556 | kWh |
Pipeline Transportation | 400 | km |
Heavy Duty Transport | Hydrogen | 0.09 | kg |
Pipeline transportation | 400 | km |
Table 9: Supply chain outputs and corresponding units. The unit products are highlighted in red.
|
Output Parameters
|
Values
|
Units
|
Steel Manufacturing
|
Steel
|
1
|
tonne
|
Hydrogen leakage
|
0.33
|
kg
|
Heavy Duty Transport
|
Heavy duty transport
|
1
|
tonne-km
|
Hydrogen leakage
|
0.0017
|
kg
|