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DOE OSTI2026

Admissible Powertrain Alternatives for Heavy-Duty Fleets: A Case Study on Resiliency and Efficiency

Heavy-duty vehicles dominate global freight movement and primarily rely on fossil-derived diesel fuel. However, fluctuations in crude oil prices and evolving emissions regulations have prompted interest in alternative powertrains to enhance fleet energy resiliency. This study paired real-world operational data from a large commercial fleet with high-fidelity vehicle models to evaluate the potential for replacing diesel internal combustion engine (ICE) trucks with alternative powertrain architectures. The baseline vehicle for this analysis is a diesel-powered ICE truck. Alternatives include ICE trucks fueled by bio- and renewable diesel, compressed natural gas (CNG) or hydrogen (H 2 ), as well as plug-in hybrid (PHEV), fuel cell electric (FCEV), and battery electric vehicles (BEV). While most alternative powertrains resulted in some payload capacity loss, the overall fleetwide impact was negligible due to underutilized payload capacity for the specific fleet considered in this study. For sleeper cab trucks, CNG-powered trucks achieved the highest replacement potential, covering 85% of the fleet. In contrast, H 2 and BEV architectures could replace fewer than 10% and 1% of trucks, respectively. Day cab trucks, with shorter daily routes, showed higher replacement potential: 98% for CNG, 78% for H 2 , and 34% for BEVs. However, achieving full fleet replacement would still require significant operational changes such as route reassignment and enroute refueling, along with considerable improvements to onboard energy storage capacity. Additionally, the higher total cost of ownership (TCO) for alternative powertrains remains a key challenge. This study also evaluated lifecycle impacts across various fuel sources, both fossil and bio-derived. Bio-derived synthetic diesel fuels emerged as a practical option for diesel displacement without disrupting operations. Conversely, H 2 and electrified powertrains provide limited lifecycle impacts under the current energy scenario. This analysis highlights the complexity of replacing diesel ICE trucks with admissible alternatives while balancing fleet resiliency, operational demands, and emissions goals. These results reflect a US-based fleet’s duty cycles, payloads, GVWR allowances, and an assumption of depot-only refueling/recharging. Applicability to other fleets and regions may differ based on differing routing practices or technical features such as battery swapping.

BEV↗

NASA NTRS1988

High/variable mixture ratio oxygen/hydrogen engines

A LOX/LH2 high/variable mixture ratio booster upper stage is described. The engine has high thrust-weight ratio as a booster and high specific impulse as an upper stage engine. Operation at high mixture ratio utilizes the propellants at high bulk density. The engine may use multiple turbopump-preburners for higher thrust ratings. The engine uses the full flow cycle to obtain minimum turbine inlet temperatures for a given chamber pressure and to avoid interpropellant shaft seals and other single point failure modes. A portion of the liquid hydrogen is used to regeneratively cool the thrust chamber assembly. The warmed hydrogen coolant is then used to drive the fuel boost turbopump. All propellants arrive at the gas-gas injector ready to burn. Shear mixing of the parallel flowing high velocity, low density fuel-rich gases with the high density, low velocity oxidizer-rich gases provides complete combustion with a modest chamber volume. Combustion stability is assured by the injection of the heated fuel-rich gases and the comparatively low volume ratio of the propellants before and after combustion. The high area ratio nozzle skirt is fitted with a low area ratio nozzle skirt insert for optimum low altitude performance. The overall engine characteristics make it a candidate for ALS, Shuttle-C, LRB, and SSTO applications.

Knuth, William H.↗

DOE OSTI2023

Solution combustion synthesis of iron-based alumina catalysts for dehydrogenation of fossil fuels

Microwave-assisted thermocatalytic dehydrogenation of fossil fuels has been proposed as a method for hydrogen production with no CO2 emissions. The byproduct is carbon, which has a commercial value. Iron-based alumina nanocomposites are promising catalysts for this process as they both absorb microwave radiation and catalyze the dehydrogenation. In addition, they may have magnetic properties, which could be used for their separation from the carbon byproduct. Solution combustion synthesis (SCS) is an attractive technique for the fabrication of iron-based alumina nanocomposites because it can produce high specific surface area oxides in a facile manner. However, the effects of the heating mode, the fuel, and the iron/aluminum ratio on the combustion synthesis behavior and the product properties have not been studied yet. In the present work, the iron-based alumina nanocomposites were obtained by SCS using a hotplate, a muffle furnace, and a microwave oven. The initial mixtures were aqueous solutions of iron nitrate, aluminum nitrate, and an organic fuel. The concentrations of the two nitrates were varied in proportion to Fe:Al molar ratios of 1:2, 1:1, and 2:1. Two fuels were tested: citric acid and glycine. The combustion was less vigorous when citric acid was used as the fuel, which is explained by the lower exothermicity of the reaction. X-ray diffraction analysis of the products confirmed the formation of complex oxides of Fe and Al, specifically it detected hercynite and magnetite phases. Brunauer-Emmett-Teller surface area analysis has shown that the powders obtained using citric acid have specific surface areas as high as 276 m2/g, significantly higher than those obtained using glycine. Muffle furnace and hotplate heating led to comparable specific surface areas, while microwave heating resulted in significantly lower specific surface areas. The magnetic properties of the products increase with increasing the Fe/Al molar ratio from 1:2 (no response to a magnetic field) to 1:1 (weak response) and 2:1 (strong response).

solution combustion synthesis, nanoscale oxides, f↗

DOE OSTI2024

Fluidized-Bed Gasification of Coal-Biomass-Plastics for Hydrogen Production

Coal is one of the most abundant fossil energy resources in the United States and in the world. The recoverable reserves in the United States are estimated to be about 252 billion tons – more than 350 years of supply at current rates of usage. However, the share of coal in total primary energy consumption in the US has been declining over the years. The decline of coal is mainly attributed to cheap natural gas and precipitous declines in the cost of electricity production from renewable technologies such as wind and solar. Coal can potentially be used if it is coupled with carbon-neutral feedstock such as biomass-agricultural residues, forest biomass, and forest residues. Co-gasification of coal and biomass can become a negative carbon emission technology if the carbon dioxide (CO 2 ) is captured and sequestered. Although the biomass gasification process has a lot of similarities to coal gasification, the large-scale adaptation of power production sourced from biomass has not come to fruition. The main reason is that the power production from biomass is still expensive when compared with natural gas or coal power technologies. To address the feedstock cost, one approach is to use low-cost feedstocks, such as municipal solid wastes (MSW) or plastics, for gasification. Gasification involves the partial oxidation of coal and/or biomass feedstocks to produce a combustible fuel called synthesis gas (syngas) which is composed of carbon monoxide (CO), hydrogen (H 2 ), CO 2 , methane (CH 4 ), nitrogen (N 2 ), water (H 2 O), and other compounds that might be considered as contaminants. Raw syngas from gasification must go through multiple steps to produce high-purity hydrogen. The specific steps depend upon the quality (gas composition, contaminants, and their concentration) and condition (pressure and temperature) of syngas. The long-term goal of the project was to utilize coal and plastics together with biomass to produce energy and fuels using a gasification platform while reducing greenhouse gas emissions. The main objective of this research was to examine gasification performance in a laboratory-scale fluidized-bed gasifier for hydrogen production. The specific objectives of the research were to: (i) study coal-plastic-biomass mixture flowability for consistent feeding in the gasifier; (ii) understand the gasification behavior of the mixture in steam and oxygen environments; (iii) perform thermal property characterization of ash and slag from the mixture feedstock and refractory-ash interface of the mixture under gasification conditions; and (iv) develop process models to determine the technology needed for syngas cleanup and contaminants. The study found that there was no apparent segregation when biomass, coal, and waste plastics were mixed together during feeding. Although there were differences in hydrogen production when individual feedstock were fed, the hydrogen concentration remained almost constant with various blends. Therefore, blending waste plastics with biomass and coal, which are all abundant, is a better approach for energy production. Results of the techno-economic analysis suggested that integration of advanced gasification (GTI’s R-GAS™) and syngas cleanup and conditioning technologies (RTI’s WDP and AFWGS) for clean hydrogen production resulted in substantial benefits, including significant capital cost and operating cost reductions. Advanced technologies resulted in 16% reduction in the hydrogen production cost (COH) from 2.94 $\$$/kg to 2.47 $\$$/g, with further scope for optimization and cost reduction. These advanced technologies also result in lower emissions, and improved energy efficiency.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1973

Hydrogen-oxygen auxiliary propulsion for the space shuttle. Volume 1: High pressure thrusters

Technology for long life, high performing, gaseous hydrogen-gaseous oxygen rocket engines suitable for auxiliary propulsion was provided by a combined analytical and experimental program. Propellant injectors, fast response valves, igniters, and regeneratively and film-cooled thrust chambers were tested over a wide range of operating conditions. Data generated include performance, combustion efficiency, thermal characteristics film cooling effectiveness, dynamic response in pulsing, and cycle life limitations.

Source record↗

NASA NTRS1995

Computational study of inlet injection for a Pre-Mixed, Shock-Induced Combustion (PM/SIC) engine

A computational simulation of reacting 2-D and 3-D flowfields in a model inlet section of a Pre-Mixed, Shock-Induced Combustion (PM/SIC) engine concept was performed. LARCK, a multi-dimensional Navier-Stokes code with finite-rate kinetics chemistry developed at NASA LaRC by J.A. White, was adapted for this simulation. The flow conditions in the simulation match those envisioned for the PM/SIC engine experiments currently planned at LaRC. The reacting flowfields were Mach 6.3 freestream air and Mach 2 hydrogen at various pressure and temperature conditions injected through a slot injector at the base of the inlet section. In the PM/SIC engine, fuel is injected at the inlet section upstream of the combustor, and reaction is initiated by the shock wave at the inlet which increases the gas temperature and pressure beyond the kinetic limits for reaction. Many challenges exist prior to establishing shock-controlled combustion as a practical engine concept. These challenges include fuel injection schemes that can provide proper fuel-air mixing without creating large losses in the inlet section, and control of the combustion process so that early ignition or combustion propagation through the inlet boundary layer does not occur. For this project, a parametrics study was carried out to model the fuel injection of hydrogen at different flow conditions. It was found that, as the fuel temperature and pressure were increased, the potential for pre-ignition was high at a short distance downstream of the slot injector. The next stage of this work will investigate injection techniques for enhancing mixing of fuel and air in a manner that prevents or reduces the potential for premature ignition observed numerically.

Gonzalez, D. E.↗

DOE OSTI2021

Preheating and premixing effects on NO x emissions in a high-pressure axially staged combustor

NO x emissions remain a primary concern for modern and future gas turbines, particularly as we progress towards a net-zero carbon future. It is critical to identify novel strategies to mitigate environmental pollutants for both modern turbines operated on natural gas and future turbines projected to use carbon-free fuels (such as hydrogen). In the current study, NO x emissions of a reacting methane-air jet in a vitiated crossflow are experimentally investigated in a model axially staged combustor at 5 atm. The combustion products from the main stage combustor flow into the axial stage at temperatures ranging from 1580 to 1650 °C. The axial stage contains a reacting jet in crossflow, which provides an overall temperature rise ranging from 50 to 220 °C to generate exit temperatures similar to gas turbine engines. The focus of this paper is to explore the effects of flame liftoff and ignition timescales on the NO x contribution of this secondary jet. This is done by varying the premixed level and preheat temperature of the axial jet. The effects are explored at different momentum flux ratios (J), jet equivalence ratios (φ jet ), exit temperatures (T exit ), and main stage (headend) temperatures (T HE ). High-speed CH* chemiluminescence imaging is employed for each test case to determine the flame stabilization point. For a given temperature rise and combustor exit temperature, an increase in ignition delay was observed with a decrease in jet temperature. This provided a NO x benefit, particularly for jets that are injected at or close to an ignitable mixture fraction. Similarly, the coaxial injector caused a significant ignition delay compared to the fully premixed injector; this also led to a NO x benefit. Overall, the results show that a thermally driven delay in the axial stage provides a greater NO x reduction than a mixing delay.

03 NATURAL GAS↗

DOE OSTI2024

Economically Viable Intermediate to Long Duration Hydrogen Energy Storage Solutions for Fossil Fueled Assets

This report was prepared as an account of work sponsored by the Office of Fossil Energy and Carbon Management of U.S. Department of Energy under Funding Opportunity Announcement Number DE-FOA-0002332 “Energy Storage for Fossil Power Generation”. The work aimed to explore and advance an innovative hydrogen energy storage system – the synergistically integrated hydrogen energy storage system (SIHES) – that has the following characteristics: • Compatible with existing or new coal and gas fuel electricity generation units, • best suited for intermediate to long duration energy storage, from 12 hours to weeks even months, and • capable of storing energy at the utility scale – hundreds of MWh to GWh energy storage with power output level in tens to hundreds of MW. Preliminary front-end engineering design (Pre-FEED) studies was carried out to develop and refine a site-specific SIHES as peaking power generation units (so named as HyPeaker) as the first market entry point, to demonstrate both the technical feasibility and the economic viability to integrate the HyPeaker “within the fence” of a fossil power plant. This specific site was TVA’s Johnsonville Combustion Turbine Plant. The HyPeaker was designed and engineered to integrate with a 60MW aeroderivative gas turbine unit already available at TVA’s Johnsonville site. This site-specific HyPeaker consists of an alkaline electrolyzer to produce hydrogen from CO 2 free electricity sources, an innovative low-cost high-pressure hydrogen storage system (Big-Ton) and the aero gas turbine to generate electricity using blend of hydrogen and natural gas. A holistic system level technoeconomic analysis tool specific to HyPeaker was developed to optimize the engineering design of the Johnsonville site-specific HyPeaker for cost and performance. The optimal design and specification of the Johnsonville site-specific HyPeaker are the following: • Alkaline electrolyzer: 3MW • Big-Ton storage vessel: 11,000kg H 2 at 3000psi. • 4-stage diaphragm hydrogen compressor: 55kg-H 2 /hr from 150psi to 3000psi. The HyPeaker is designed to provide sufficient hydrogen for 90% continuous operation of the HyPeaker. All major components have design life of 30 years. The capex of HyPeaker is estimated at $\$$7.1M. This included $\$$1.5M for the electrolyzer, $\$$5.6M for the storage vessel and compressor. The cost of aero gas turbine was included as it is already available at the site. Key findings are: • HyPeaker can be designed, manufactured, installed and integrated with the fossil power plants, with sub-systems and components commercially available on the market today, even when it is scaled up to an order of magnitude larger than the one at the Johnsonville site. HyPeaker is a technologically viable solution to cover a wide range of energy storage duration needs, from daily peaking operation to seasonal shifting for fossil fueled assets. • The cost advantage of SCCV based Big-Ton H 2 storage vessel made it possible to “oversize” the H 2 storage subsystem to achieve overall system level cost optimization. The benefits are two-fold. First, it allows to significantly reduce the capacity and cost of electrolyzer by spreading H 2 production over a much longer period of time when the fuel cost for electricity production is low. Second, it allows to balance the hydrogen production and usage shift over weeks to months to meet the peak demands. As such, the capital cost of HyPeaker system using the Big-Ton was less than half of the cost of a system with today’s steel tube based H 2 storage system. The HyPeaker has even better cost advantage Li-ion battery based energy storage system. The estimated capital cost of Li-Ion battery system would be at $\$$38M, under the same projected 20-year electricity generation profile of the Johnsonville site. This is over 5 times more expensive than the HyPeaker system. • Since industry scale energy storage systems do not have 100% energy conversion and storage efficiency, energy storage systems using fossil fuel generated electricity would increase the CO 2 emission. This is particularly the case for HyPeaker due to its low round trip efficiency. Therefore, a more sensible solution would be to the excessive or curtailed electricity from CO 2 emission free sources such as solar farms, wind farms or nuclear power plants, to produce hydrogen, and integrate them with the HyPeaker. Electricity from TVA’s nuclear power plants was used for the Johnsonville HyPeaker. • The economic viability of HyPeaker is expected to be further improved when global supply chains are taken into consideration. For the same Johnsonville site specific HyPeaker, the capex would be reduced to ~$\$$3.6M from ~$\$$7.1M, and the added LCOE is reduced to ~$\$$85/MWh. With the bipartisan Infrastructure Investment and Jobs Act, the cost of domestically produced HyPeaker sub-systems would be at the level of today’s global suppliers. Since the peaking units generally operate at peak usage period, thereby demanding higher price, the projected $\$$85/MWh LCOE would be within the realm of financial viability for utility operators.

08 HYDROGEN↗

NASA NTRS1983

A reexamination of the laser supported combustion wave

Kantrowitz (1972) and Minovitch (1972) have proposed the use of laser sustained plasmas as a means to heat a rocket propellant. Recent studies of laser-powered propulsion have been directed toward the application of high-specific-impulse space propulsion systems for orbital transfer missions. Analyses of rocket performance relied heavily on the concept of the laser-supported combustion (LSC) wave. Raizer (1971) first drew the analogy between laser-sustained plasmas and combustion waves in an analysis. The Raizer model was later applied to hydrogen by Kemp and Root (1979). In connection with certain problems arising with the approach considered by Kemp and Root, the present investigation is concerned with a reexamination of the Raizer model. Attention is given to a numerical approach for the entire LSC wave in hydrogen, taking into account the incorporation of the proper boundary conditions far downstream of the wave.

Keefer, D.↗

DOE OSTI2023

Durable Fuel Cell MEA through Immobilization of Catalyst Particle and Membrane Chemical Stabilizer

For hydrogen-based fuel cell electric vehicle to be cost competitive with the incumbent diesel-powered internal combustion engine heavy-duty vehicle, the total cost of ownership of the truck must be decreased via both capital cost and the operating cost (H 2 fuel expense) reduction. This puts the emphasis on the decrease of fuel cell stack cost via use of low platinum catalyst material usage to decrease capital cost, high H 2 fuel efficiency and high stack durability to decrease the operating cost. US DOE has set a target of ≤ 0.25 mgPt/cm 2 total loading in the membrane electrode assembly, high fuel efficiency of > 68% and a HD-combined target of ≥ 2.5 kW/gPGM after running an accelerated stress test (AST) equivalent to 30,000 hours of heavy-duty fuel cell operation.

08 HYDROGEN↗

DOE OSTI2025

Beta-Amino Carboxylate (BAC) non-aqueous physical solvents for enhanced CO2 separations in pre-combustion carbon capture, industrial CO 2 capture, and biogas upgrading processes

Novel beta-amino carboxylate (BAC) solvents have been synthesized and tested to efficiently capture carbon dioxide (CO 2 ) from process gas streams with CO 2 partial pressure intermediate between pre-combustion and post-combustion capture. The BAC solvents have molecular structures characterized by alkyl-substituted amides or esters containing a secondary amine functional group on the second carbon from the carbonyl carbon (referred to as the beta “β” carbon). The ester or amide functional group combined with optimal steric crowding around the amine nitrogen by proximate alkyl groups are tailored to modify the strength of CO 2 binding in the solvent. The solvents possess high CO 2 solubilities and high gas selectivity including good CO 2 /H 2 O selectivity and can be utilized for CO 2 absorption over a range of partial pressures. Due to low volatility, many of the solvents can be operated at or above ambient temperature which eliminates solvent chilling and allows regeneration using low grade waste heat. These novel solvents offer an opportunity for efficient carbon capture for a range of applications including biogas upgrading, hydrogen production, and pre-combustion carbon capture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1997

Imaging Fluorescent Combustion Species in Gas Turbine Flame Tubes: On Complexities in Real Systems

Planar laser-induced fluorescence (PLIF) is used to visualize the flame structure via OH, NO, and fuel imaging in kerosene- burning gas turbine combustor flame tubes. When compared to simple gaseous hydrocarbon flames and hydrogen flames, flame tube testing complexities include spectral interferences from large fuel fragments, unknown turbulence interactions, high pressure operation, and the concomitant need for windows and remote operation. Complications of these and other factors as they apply to image analysis are considered. Because both OH and gas turbine engine fuels (commercial and military) can be excited and detected using OH transition lines, a narrowband and a broadband detection scheme are compared and the benefits and drawbacks of each method are examined.

Hicks, Y. R.↗

DOE OSTI2021

The preparation and characterization of chemically deuterium incorporated cotton fibers

Preparation of deuterium incorporated cellulose is a vital tool to investigate cellulose internal structure and to expand the application fields of cellulose materials. In this study, cellulosic cotton fibers with anti-rehydration (exchange-resistant) deuterium incorporated in cellulose were prepared by chemical hydrogen–deuterium exchange treatment. The chemical hydrogen–deuterium exchange process, along with exchange time, were characterized by nuclear magnetic resonance hydrogen spectroscopy (1H-NMR). The anti-rehydration deuterium incorporation was determined by Fourier Transform infrared spectroscopy (FTIR) and Stable Isotope Ratio Mass Spectrometer (IRSM). Here, the effect of the deuterium hydroxyl substitution on cotton fiber’s spectral data, microstructure, crystalline information, degree of polymerization, as well as it’s thermogravimetric analysis (charcoalization and combustion) are explored. Analysis of the chemical exchange process indicated that the hydrogen–deuterium exchange occurred preferentially in the amorphous cellulose component over the first several minutes. Deuterium exchange in the anti-rehydration crystalline phase took several hours. Increasing the treatment time, enhanced exchange-resistant deuterium incorporation to as high as about 60% of the cotton fibers’ cellulose hydroxyl groups was achieved. The characterization of FTIR, Fourier transform Raman (FT-Raman), and near-infrared spectra (NIR) all exhibited the deuterium spectral isotope effect on cellulose hydroxl groups. While, apart from the effect of reaction temperature, deuterium incorporation isotope effect did not affect the cellulose microstructure, crystalline index and the degree of polymerization properties. Furthermore, the thermogravimetric analysis of deuterated cotton fibers under N 2 and air atmosphere were both altered due to the thermodynamic isotope effect. These observations revealed the hydrogen–deuterium exchange treatment process and impacts on cellulose fiber properties, which helped us to better understand the cellulose internal structure and may facilitate the potential utilization of deuterated cellulosic materials.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1990

A comparison of analytical results for 20 K LOX/hydrogen instabilities

Test data from NASA Lewis' Effect of Thrust Per Element on Combustion Stability Characteristics of Hydrogen-Oxygen Rocket Engines test program are used to validate two recently released stability analysis tools. The first tool is a design methodology called ROCCID (ROCket Combustor Interactive Design). ROCCID is an interactive design and analysis methodology that uses existing performance and combustion stability analysis codes. The second tool is HICCIP (High frequency Injection Coupled Combustion Instability Program). HICCIP is a recently developed combustion stability analysis model. Using a matrix of models, results from analytic comparisons with 20 K LOX/H2 experimental data are presented.

Klem, Mark D.↗

NASA NTRS1990

A comparison of analytical results for 20 K LOX/hydrogen instabilities

Klem, Mark D.↗

NASA NTRS1992

Mixing and combustion effects in a sliding-wedge ram accelerator with hydrogen injection

The ram accelerator concept has been envisioned as the basis of a ground-based flight-test facility concept in which the test section follows the ram-accelerated projectile, and allows hydrogen mixing/combustion experiments to be conducted when hydrogen carried by the projectile is injected into the freestream. A numerical simulation is presently conducted for such mixing and combustion; the chemical reactions in question are modeled using a seven-step, seven-species model. A grid-adaptation procedure is used to resolve flow features in areas of high fluid and species gradients.

Ramakrishnan, R.↗

NASA NTRS2002

Computational Study of Near-limit Propagation of Detonation in Hydrogen-air Mixtures

A computational investigation of the near-limit propagation of detonation in lean and rich hydrogen-air mixtures is presented. The calculations were carried out over an equivalence ratio range of 0.4 to 5.0, pressures ranging from 0.2 bar to 1.0 bar and ambient initial temperature. The computations involved solution of the one-dimensional Euler equations with detailed finite-rate chemistry. The numerical method is based on a second-order spatially accurate total-variation-diminishing (TVD) scheme, and a point implicit, first-order-accurate, time marching algorithm. The hydrogen-air combustion was modeled with a 9-species, 19-step reaction mechanism. A multi-level, dynamically adaptive grid was utilized in order to resolve the structure of the detonation. The results of the computations indicate that when hydrogen concentrations are reduced below certain levels, the detonation wave switches from a high-frequency, low amplitude oscillation mode to a low frequency mode exhibiting large fluctuations in the detonation wave speed; that is, a 'galloping' propagation mode is established.

Yungster, S.↗

DOE OSTI2025

Life cycle assessment of a novel gas switching reforming for sustainable hydrogen production with CO2 capture

Gas switching reforming for hydrogen production (GSR-H2) presents an efficient, low-carbon hydrogen production method that incorporates integrated carbon capture, offering efficiency gains over traditional methods such as proton exchange membrane (PEM) electrolysis, steam methane reforming (SMR) and the newer method of chemical looping reforming (CLR). GSR-H2 has been demonstrated in lab scale which operates as an exothermic process that eliminates the need for additional natural gas combustion, using its own waste heat to generate process steam and partially offset energy usage through electricity production. Beyond its thermal self-sufficiency, GSR-H2 advances upon CLR by integrating all reaction stages within a single reactor cluster, eliminating the complexities of solid circulation, reducing capital costs, and enhancing overall process efficiency. This streamlined design simplifies scale-up and enables inherent CO2 separation with minimal energy penalty, making GSR-H2 a highly competitive pathway for low-carbon hydrogen production. This study presents the first life cycle assessment (LCA) of GSR-H2, offering a novel evaluation of this new process’s environmental impacts across diverse energy scenarios. Key findings reveal that in the renewables-powered scenario, GSR-H2 achieves a GWP of 2.77 kg CO2 eq per kg H2, a substantial improvement over SMR’s 10.4 kg CO2 eq and close to the low emissions of CLR (1.84 kg CO2 eq) and PEM electrolysis (1.85 kg CO2 eq). These results demonstrate GSR-H2’s competitive advantage as a lower-emission alternative, combining design simplicity and efficiency gains, especially in renewable-integrated systems. These results establish GSR-H2 as a competitive, scalable option for hydrogen production, particularly in decarbonization efforts.

03 NATURAL GAS↗