Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods
Blue hydrogen is a key pathway for reducing greenhouse gas emissions while utilizing natural gas with carbon capture and storage (CCS). This study conducts a techno-economic and environmental analysis of a greenfield blue hydrogen plant in Saskatchewan, Canada, integrating both SMR and ATR technolog...
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MDPI AG
2025-06-01
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| Series: | Energies |
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| Online Access: | https://www.mdpi.com/1996-1073/18/13/3272 |
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| author | Mohammad Sajjadi Hussameldin Ibrahim |
| author_facet | Mohammad Sajjadi Hussameldin Ibrahim |
| author_sort | Mohammad Sajjadi |
| collection | DOAJ |
| description | Blue hydrogen is a key pathway for reducing greenhouse gas emissions while utilizing natural gas with carbon capture and storage (CCS). This study conducts a techno-economic and environmental analysis of a greenfield blue hydrogen plant in Saskatchewan, Canada, integrating both SMR and ATR technologies. Unlike previous studies that focus mainly on production units, this research includes all process and utility systems such as H<sub>2</sub> and CO<sub>2</sub> compression, air separation, refrigeration, co-generation, and gas dehydration. Aspen HYSYS simulations revealed ATR’s energy demand is 10% lower than that of SMR. The hydrogen production cost was USD 3.28/kg for ATR and USD 3.33/kg for SMR, while a separate study estimated a USD 2.2/kg cost for design without utilities, highlighting the impact of indirect costs. Environmental analysis showed ATR’s lower Global Warming Potential (GWP) compared to SMR, reducing its carbon footprint. The results signified the role of utility integration, site conditions, and process selection in optimizing energy efficiency, costs, and sustainability. |
| format | Article |
| id | doaj-art-1b2171b6cefb4babb3f23f84743c20c6 |
| institution | Kabale University |
| issn | 1996-1073 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Energies |
| spelling | doaj-art-1b2171b6cefb4babb3f23f84743c20c62025-08-20T03:50:16ZengMDPI AGEnergies1996-10732025-06-011813327210.3390/en18133272Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production MethodsMohammad Sajjadi0Hussameldin Ibrahim1Clean Energy Technologies Research Institute (CETRI), Process Systems Engineering, Faculty of Engineering and Applied Science, University of Regina, 3737 Wascana Parkway, Regina, SK S4S 0A2, CanadaClean Energy Technologies Research Institute (CETRI), Process Systems Engineering, Faculty of Engineering and Applied Science, University of Regina, 3737 Wascana Parkway, Regina, SK S4S 0A2, CanadaBlue hydrogen is a key pathway for reducing greenhouse gas emissions while utilizing natural gas with carbon capture and storage (CCS). This study conducts a techno-economic and environmental analysis of a greenfield blue hydrogen plant in Saskatchewan, Canada, integrating both SMR and ATR technologies. Unlike previous studies that focus mainly on production units, this research includes all process and utility systems such as H<sub>2</sub> and CO<sub>2</sub> compression, air separation, refrigeration, co-generation, and gas dehydration. Aspen HYSYS simulations revealed ATR’s energy demand is 10% lower than that of SMR. The hydrogen production cost was USD 3.28/kg for ATR and USD 3.33/kg for SMR, while a separate study estimated a USD 2.2/kg cost for design without utilities, highlighting the impact of indirect costs. Environmental analysis showed ATR’s lower Global Warming Potential (GWP) compared to SMR, reducing its carbon footprint. The results signified the role of utility integration, site conditions, and process selection in optimizing energy efficiency, costs, and sustainability.https://www.mdpi.com/1996-1073/18/13/3272hydrogencarbon capturegreenfield plant designprocess simulationTEA |
| spellingShingle | Mohammad Sajjadi Hussameldin Ibrahim Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods Energies hydrogen carbon capture greenfield plant design process simulation TEA |
| title | Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods |
| title_full | Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods |
| title_fullStr | Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods |
| title_full_unstemmed | Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods |
| title_short | Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods |
| title_sort | case study of a greenfield blue hydrogen plant a comparative analysis of production methods |
| topic | hydrogen carbon capture greenfield plant design process simulation TEA |
| url | https://www.mdpi.com/1996-1073/18/13/3272 |
| work_keys_str_mv | AT mohammadsajjadi casestudyofagreenfieldbluehydrogenplantacomparativeanalysisofproductionmethods AT hussameldinibrahim casestudyofagreenfieldbluehydrogenplantacomparativeanalysisofproductionmethods |