Gas Switching Reforming (GSR) is an innovative reforming technology that integrates inherent CO₂ capture, making it a promising solution for low-emission hydrogen and power production. This study presents a comprehensive techno-economic assessment of the GSR process, which consists of a reforming reactor, a water-gas shift unit, a pressure swing adsorption (PSA) unit, a gas turbine, and a heat recovery steam generation system. The significance of carbon capture and hydrogen production has been emphasized by global organizations such as the International Energy Agency (IEA) and the Intergovernmental Panel on Climate Change (IPCC), which suggest that fuel switching and carbon capture utilization and storage (CCUS) technologies will play a pivotal role in reducing global CO₂ emissions [1]. As natural gas is expected to become the second-largest fuel source by 2030, technologies like GSR present a viable pathway for decarbonization [2]. Compared to conventional reforming techniques such as steam methane reforming (SMR) and chemical looping reforming (CLR), GSR demonstrates superior CO₂ capture rates and cost-effectiveness due to its single-reactor configuration, which enhances scalability and operational efficiency.

To evaluate the economic and technical performance of GSR, a detailed techno-economic analysis was conducted. The GSR reactor was modeled using a 0D simulation framework coded in MATLAB R2023b, while process components such as heat exchangers, boilers, reactors, compressors, and expanders were simulated using Aspen HYSYS V12.1. The PSA unit was represented as a “black box” with an assumed H₂ purity of 99.99% and an 86% recovery rate [3]. Additionally, the combined cycle power plant was modelled using the Thermoflex component of the Thermoflow Suite V32. Economic metrics, including LCOE and LCOH, were estimated following the methodology outlined by the Global Carbon Capture and Storage Institute (GCSI) [4]. Various gas turbines were considered based on their operational fuel flow rates to determine optimal configurations for hydrogen and power generation.

The study's findings highlight the competitiveness of the GSR technology in both hydrogen and power production. The process flow remains largely consistent across different scenarios, with the primary distinction being that GSR-H₂ compresses hydrogen to 150 bar for transport and storage, while GSR-CC combusts the produced hydrogen to generate electricity. The electrical efficiency of the process varied between 30% and 48%, with the LCOE ranging from $93.9/MWh to $140/MWh. The highest efficiency and lowest LCOE were observed when utilizing the Mitsubishi MPA FT8-3 gas turbine, emphasizing the importance of turbine selection in process optimization. The GSR-H₂ process achieves a CO₂ capture efficiency of 96% while maintaining a competitive levelized cost of hydrogen (LCOH) at $1.99/kg-H₂, demonstrating its feasibility as an efficient and environmentally friendly hydrogen and power generation process.

Although the GSR process utilizes largely established technologies, the long-term stability of the oxygen carrier remains a key area for further research. Future work will focus on testing different oxygen carrier materials to improve process durability and efficiency. Additionally, sensitivity analyses on gas prices and reactor sizes will provide deeper insights into the economic viability of large-scale GSR implementation. The results of this study demonstrate the potential of GSR as a scalable, cost-effective, and sustainable hydrogen and power generation technology, positioning it as a viable alternative for decarbonizing the energy sector.

References

1. Change, I. P. O. C., 2007, "Climate Change 2007: Synthesis Report," Geneva: IPCC, 337.
2. 2019, The future of hydrogen: seizing today’s opportunities. International Energy agency
3. Nazir, S. M., Cloete, J. H., Cloete, S., 2019, "Efficient Hydrogen Production with CO2 Capture using Gas Switching Reforming," Energy, 185, pp. 372.
4. Booras, G., Davison, J., Ekstrom, C., 2013, "Toward a Common Method of Cost Estimation for CO2 Capture and Storage at Fossil Fuel Power Plants,".