The research focus of the Institute of Plant and Process Technology is on hydrogen production using various water electrolysis technologies and steam reforming of biogas. This hydrogen serves as feedstock for the synthesis of various hydrogen derivatives. To better assess electricity-based hydrogen and integrated processes, they are compared to conventional production methods based on fossil resources such as natural gas.

In addition to green hydrogen production in Germany and the necessary upscaling of electrolysis technologies, the import of hydrogen and its derivatives is required to meet current and future hydrogen demand. In this context, the institute is working on the recovery of hydrogen from ammonia at a desired location through a process known as Ammonia Cracking.

Website: Research at APT 
Contact: Sebastian Rehfeldt

In addition to the production of hydrogen by water electrolysis and steam reforming of biogas, the Institute of Plant and Process Technology is focusing on the conversion of hydrogen to various hydrogen derivatives. In particular, the ammonia and methanol processes are investigated through process simulations. One of the primary objectives of this research is to develop design and operational strategies for the flexible operation of ammonia plants. Moreover, material and heat integration potentials within the overall process chain of e-methanol production are identified and assessed. To investigate different operation strategies and the flexibility of an e-methanol process, a digital twin is developed for a methanol plant at a container scale.

Website: Research at APT 
Contact: Sebastian Rehfeldt

Reducing greenhouse gases in the mobility sector is one of the most important challenges to stop climate change. Besides battery technology, hydrogen-fueled vehicles are the focus of research and development. Especially for long-distance commercial vehicles, the hydrogen fuel cell is an ideal solution. For this purpose, a highly efficient hydrogen tank is required. The storage of cryogenic compressed hydrogen gas (CcH2) is a promising storage technology and enables high storage densities.

However, storage technologies with gaseous hydrogen can also be used advantageously for the regional, decentralized production and distribution of hydrogen. A particular focus here is on so-called multi-element gas carriers (MEGC). MEGCs are transportable hydrogen storage containers in which hydrogen is stored in several pressure vessels at elevated pressure and ambient temperatures.

Also in aviation, the use of green hydrogen as a propulsion system for larger commercial aircraft offers significant potential for emission reduction. Alongside the development of new propulsion systems and aircraft concepts, establishing a corresponding hydrogen infrastructure is crucial. Creating long-term perspectives and defining transition pathways within the framework of a global energy transition are central to this endeavor. This requires a comprehensive examination of the technical, economic, and ecological aspects of the supply chain, which is addressed in the institute’s research.

Website: Research at APT
Contact: Sebastian Rehfeldt

Series production and industrialization of integrated & sector-coupled electrolysis systems for water

The market scale-up of the production of green hydrogen and its derivatives, as well as hydrogen application technologies, is intended to be further accelerated according to the continuation of the German National Hydrogen Strategy. In Germany, at least 10 gigawatts of electrolysis capacity for green hydrogen production should be installed by 2030. This ambitious goal necessitates a significant upscaling of electrolysis technology, a challenge addressed in the flagship project H₂Giga. Through mass production of electrolysis stacks and increased electrolysis plant capacities, investment costs can be reduced, which enhances the economic viability compared to conventional processes and later, in particular, impacts the hydrogen production costs in dynamic operation with reduced operating hours. Lower investment costs are also expected to open up new markets and facilitate the utilization of hydrogen in additional sectors.

The Institute of Plant and Process Technology is investigating the material and thermal process integration of green hydrogen produced through electrolysis into chemical production processes such as ammonia or methanol. At present, the focus is on the flexibilization of ammonia plants to enable an increasingly dynamic operation. Ultimately, integration possibilities and design parameters for electrolyzers are being identified to develop a requirement catalogue for the optimal integration of various downstream processes with water electrolysis. Additionally, additive manufacturing possibilities in the periphery of electrolysis plants are being explored.

To improve the theoretical models of PEM electrolysis, they are continuously updated according to the latest findings from the literature. However, literature datasets are often incomplete or significantly deviate from each other. To understand these variations and obtain experimental results at the stack level rather than the cell level, a 10 kW PEM electrolysis test rig is built within the project. The focus of the test rig is the investigation of undesired gas crossover of the product gases through the membrane under different operating conditions.

Development of a Power-to-Methanol Process

Site-specific solutions are required for essential chemical sites in Germany, such as Burghausen/ChemDelta Bavaria, to achieve climate neutrality in the future while remaining economically viable. In the H2-Reallabor project, container concepts, so-called living labs, are developed to investigate possible solutions and increase their technical readiness level. The container solutions are constructed and measurements are conducted location-independently and later tested under real conditions in an industrial environment.

The direct conversion of hydrogen from electrolysis and carbon dioxide to methanol (power-to-methanol) is investigated in one of several containers. The carbon dioxide is captured in another container, which will be carried out in an industrial environment from the flue gas of a residue incineration plant. As part of the project, the Institute of Plant and Process Technology is working on the development and scaling of the digital twin of the power-to-methanol plant. In addition, various possibilities for the material and heat integration of PEM electrolyzers for hydrogen production and methanol synthesis are evaluated and requirements for PEM electrolyzers for optimal integration are derived. In the preceding carbon capture container, the institute is also investigating the selection and design of the absorber and desorber columns of an amine wash process.

Component and System Modeling of Hydrogen Supply Networks for Air Transport

Ammonia cracking: Ammonia as a hydrogen carrier or intercontinental transport

The availability of large quantities of “green” hydrogen is crucial on the road to decarbonizing the German economy. However, as the national production of green hydrogen in Germany is not sufficient for the national decarbonization targets, the German government is relying on extensive imports from regions with cheap renewable energies. The conversion of hydrogen into ammonia, which has a high hydrogen density, makes sense for energy-efficient hydrogen transportation. The hydrogen is recovered from ammonia at the destination by means of ammonia cracking. The state of the art is that ammonia cracking has so far only been used industrially for small niche applications, with only small hydrogen flows (typical size: 1-2 tons per day). Against the background of national climate protection targets, the desired reduction in CO2 emissions and the tight supply situation for energy raw materials, the HyPAC research project aims to transform the German economy on a hydrogen basis. As part of HyPAC, a new process for producing hydrogen from ammonia is to be developed and demonstrated for the first time in a mini plant. The project aims at an industrial, easily scalable and energy-efficient ammonia cracking process to produce hydrogen on a large scale (ca. 500 tons per day) in high purity and at attractive price paths centrally and to provide it for large industrial customers, such as the chemical industry, hydrogen pipeline network or gas turbines.

As part of the project, the Institute of Plant and Process Technology is involved in the experimental investigation of catalysts and ideal process conditions. In addition, reactor and process models are being created to enable a techno-economic investigation. For this purpose, the entire process is simulated, taking energy integration into account. On this basis, a Life Cycle Assessment (LCA) is carried out.

Type: Collaborative project: HyPAC – Ammonia as a hydrogen carrier or intercontinental transport
Funding: German Federal Ministry of Economic Affairs and Climate Action (BMWK)
Funding code: 03EI3088B
Runtime: 01.07.2023 – 30.06.2026
Website: HyPAC
Contact: Bruno Villela Pedras Lago, Sebastian Wodak 

Development of a cryogenic hydrogen gas storage for application in long-distance commercial vehicles

The development and optimization of a cryogenic hydrogen tank system in application for trucks is the focus of the CryoTRUCK research project. The scientific work is to set up appropriate thermodynamic models and simulation models for heat transfer and cold storage. Based on this, the processes of refueling and fuel withdrawal will be simulated dynamically. Experimental investigations on cold storage systems are also planned with the project partners. Both the modelling and the experimental validation are the basic building blocks in order to integrate the CcH2 storage system into vehicles.

Type: Collaborative project: CryoTRUCK
Funding: German Federal Ministry for Digital and Transport (BMDV)
Funding code: 03B10411E 
Runtime: 01.01.2022 - 31.05.2025
Website: CryoTRUCK
Contact: Johannes Hamacher, Alexander Stary, Daniel Siebe, Laura Stops 

Development and demonstration of two technologies for the refueling of aircrafts with liquid hydrogen: Direct refueling and tank swap technology

The objective of the project is to develop two refueling technologies and demonstrate them at airports in Milan and Paris. The direct refueling of an aircraft with liquid hydrogen and a tank exchange technology in which an empty tank is replaced by a full tank are being investigated. The Institute of Plant and Process Technology is working on the development and modeling of a direct refueling system based on a liquid hydrogen centrifugal in cooperation with Linde plc. The required pump is being developed and tested in a test facility. In addition, a dynamic model for the loading and unloading processes of liquid hydrogen is being developed and used to optimize the overall system.

Type: EU project ALRIGH2T
Funding: European Climate, Infrastructure and Environment Executive Agency (CINEA)
Funding code: 101138105
Runtime: 01.01.2024 - 01.01.2028
Website: ALRIGH2T
Contact: Fabian Primke
Further information: ALRIGH2T Website

Hydrogen is regarded as one of the future energy carriers and is the feedstock for numerous syntheses. However, transporting and storing hydrogen poses a challenge. This can be done in liquid form so that hydrogen liquefaction is a crucial process today and in the future.

This course follows the lecture “Principles of Refrigeration and Industrial Low Temperature Systems”. First, the production, use and handling of hydrogen, as well as hydrogen liquefaction, will be taught and discussed as part of a lecture. Also, insights are given into project workflows and project phases in the engineering sector. The students then simulate selected cryogenic processes, including a hydrogen liquefaction process, using the process simulation program UniSim® Design. Students learn how to use UniSim® Design and gain an in-depth understanding of cryogenic liquefaction processes.

More information: TUMonline