Process Technology Training Series
H2 Production
Module from the Process Technology Training Series curriculum.
Hydrogen Production Technologies · Commercial & Emerging Routes
| Technology | Feedstock | Efficiency (HHV %) | CO2 Intensity (kg CO2/kg H2) | LCOH Range ($/kg) | Typical Scale | TRL |
|---|---|---|---|---|---|---|
| SMR (Steam Methane Reforming) | Natural gas | 75–80 | 8.0–12.0 | 1.20–1.80 | 100 TPD–1000 TPD | 9 |
| ATR (Auto-Thermal Reforming) | Natural gas, biogas | 65–75 | 5.0–10.0 | 1.50–2.20 | 50 TPD–500 TPD | 9 |
| SMR + CCS (Blue H2) | Natural gas (+ capture) | 70–75 | 0.5–1.5 | 2.00–3.50 | 50 TPD–500 TPD | 9 |
| Coal Gasification | Coal, petcoke | 55–65 | 15.0–25.0 | 1.50–2.50 | 100 TPD–500 TPD | 8–9 |
| PEM Electrolysis | Water + electricity (grid/renewable) | 65–75 | 3.5–12.0 (grid-dependent) | 3.00–6.00 | 1 TPD–50 TPD (scaling) | 8–9 |
| Alkaline Electrolysis | Water + electricity | 60–70 | 4.0–13.0 (grid-dependent) | 2.50–5.50 | 50 TPD–500 TPD | 9 |
| SOEC (Solid Oxide Electrolysis) | Water (steam) | 80–85 | 2.0–8.0 (if green) | 4.00–8.00 | <10 TPD (pilot) | 6–7 |
| Bio-Fermentation | Biomass, organic waste | 40–55 | –2.0 to 2.0 (net-negative potential) | 4.00–8.00 | 0.1–5 TPD | 5–6 |
| Thermochemical Water Splitting | Solar/nuclear heat (high-temp) | 40–50 | 0 (if renewable/nuclear) | 5.00–10.00 | Pilot-scale | 5–6 |
| Key Performance Metrics | ||||||
| Metric | SMR | ATR | PEM | Alkaline | SOEC | Definition/Notes |
| Electrochemical efficiency | — | — | 65–75% | 60–70% | 80–85% | Electrical input to H2 LHV |
| Thermal efficiency (SMR/ATR) | 75–80% | 65–75% | — | — | — | Natural gas chemical energy → H2 LHV |
| Capital cost (2024) | $1–2M/TPD | $1.5–3M/TPD | $2–4M/TPD | $1–3M/TPD | $3–6M/TPD | Installation + equipment, specific |
| Operating cost (fuel + maintenance) | $300–500/kg | $350–600/kg | $400–800/kg | $350–700/kg | $500–1000/kg | Variable, grid rates critical for e- |
| Ramp rate (response) | Slow (30–60 min) | Slow (30–60 min) | Very fast (sec–min) | Fast (5–15 min) | Moderate (10–30 min) | Load change response capability |
| Purity | 99.0–99.5% | 99.0–99.5% | 99.9%+ | 99.5–99.9% | 99.5%+ | PSA/membrane dependent for SMR/ATR |
| Waste/by-product | CO2 (8–12 kg/kg H2) | CO2 + H2O | Water | Water | O2 (8 kg/kg H2) | Environmental/market value |
| Carbon footprint (gray H2) | Gray: 8–12 | Gray: 5–10 | Green: 0–0.5* | Green: 0–0.5* | Green: 0–0.2* | kg CO2-eq/kg H2; *assumes renewable |
| Emerging Routes & Timelines | ||||||
| PEM electrolysis scaling rapidly (2024–2030 cost target: $2–3/kg); green hydrogen cost parity with SMR expected 2030–2035 if renewable power <$30/MWh. SOEC and thermochemical routes mature 2035+. Hydrogen production critical bottleneck for eFuels and ammonia synthesis scaling. |
Source: Process_Technology_Training_Series_v1.xlsx · Sheet: H2 Production
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