TYLER CAMPBELL, Managing Editor 

H₂ PRODUCTION 

NETL researchers gasify plastic waste with coal and biomass for improved H₂-rich gas production 

NETL researchers are closing in on a more effective and less expensive way to combine a growing accumulation of plastic waste with coal and biomass for a steam gasification process that can produce hydrogen (H₂)-rich synthetic gas (syngas)—a versatile gas that can be used as a fuel or as a building block for a range of chemicals that can help tackle critical energy challenges. 

Low-density polyethylene (LDPE) is a thermoplastic polymer used in packaging, bags, containers and other applications. High-density polyethylene (HDPE) is derived from petroleum and is commonly used in food and beverage containers, cleaning product bottles and pipes. HDPE and LDPE account for most discarded plastics because of their widespread single-use applications. 

According to a team of NETL researchers led by Ping Wang, steam gasification—a thermochemical process that converts carbonaceous materials like biomass or coal into syngas and H₂ with high H₂ yield and improved syngas quality—provides a promising pathway for transforming leftover plastics and other materials into valuable products. 

Traditional approaches to gasify plastic waste present specific problems. For example, the low melting points of plastics make them prone to agglomeration—when particles stick together—leading to clogging and flow obstruction in gasifiers. Plastics also require energy-intensive size reduction processes like shredding, crushing and grinding to achieve uniform particle sizes, which are essential to maintain consistent reaction kinetics and increase operational expenditures (OPEX). Tar formation from the highly volatile content of plastics can also reduce process efficiency. 

NETL researchers say they believe the gasification of plastic waste using coal refuse in the process can overcome a range of barriers facing effective plastic gasification because coal waste contains varying amounts of alkali and alkali earth metals, which can catalyze char gasification and tar cracking. 

For more information, visit: https://netl.doe.gov/ 

EVE Hydrogen Energy ships modular H₂ production system to Shandong industrial firm 

EVE Hydrogen Energy's modular H₂ production system has been shipped to an industrial company in Shandong Province, China. Deeply customized for industrial scenarios, this system integrates independently developed core technologies and features high efficiency, stability and strong adaptability that can accurately meet the stringent requirements of industrial H₂ use. 

This shipment not only marks the first onsite application of the company's modular H₂ production system in the industrial sector, but also represents a significant breakthrough in the penetration of anion exchange membrane (AEM) H₂ production technology into the real economy. It signifies a crucial step forward for H₂ energy in industrial carbon reduction scenarios and provides a practical H₂ energy solution for the green transformation of the industrial sector. 

For more information, visit: http://en.evehydrogen.com/product/product_center.html 

H₂ EQUIPMENT 

National Grid Ventures to install 100% H₂-fueled commercial linear generator 

National Grid Ventures (NGV) has announced it will install the first commercially-deployed, 100% H₂-fueled linear generator in the world at its Northport Power Plant in Fort Salonga, New York (U.S.), supported by the New York State Energy Research and Development Authority (NYSERDA) and the Long Island Power Authority (LIPA). The remaining funding is provided directly by NGV, while Stony Brook University and Mainspring Energy are also essential project partners. 

The linear generator produces power through a low-temperature, flameless chemical reaction and can be used during periods of peak demand. For the 12-mos testing period, it will run on 100% green H₂, while undergoing rigorous testing. The linear generator is expected to be operational by September 2026. 

The New York Independent System Operator (NYISO) anticipates that at least 20 gigawatts (GW) of dispatchable emissions-free resources (DEFR) will be needed by 2040 to support New York's clean energy mandates, according to its 2023–2042 System & Resource Outlook. This figure will contribute to replacing current fossil fuel generation and transitioning towards a zero-carbon electric grid. 

The program will prove the linear generator’s viability as a DEFR for Long Island’s electrical grid that can be quickly brought online to supplement other generation sources during times of peak demand. Once operation begins in 2026, it will undergo a thorough independent evaluation at the Advanced Energy Research and Technology Center (AERTC) at Stony Brook University. The Department of Mechanical Engineering’s Assistant Professor Dimitris Assanis will lead the team that will design the framework and methodologies required to ensure the linear generator’s performance, emissions, efficiency and noise levels are suitable for the needs of the local power grid both today and into the future.   

Mainspring’s linear generators are fuel-flexible, meaning they can change fuel sources in real time while in operation. Fuel sources include H₂, biogas, natural gas or any blends of these. Further, the products do not require high-purity H₂. This fuel flexibility ensures that the linear generator capacity can stay online when needed most. 

The project will create 35–50 local engineering and construction jobs and expand the skillsets of 30–40 members of NGV’s existing workforce on Long Island, while supporting the development of a H₂ ecosystem in New York State. 

For more information, visit: https://www.nationalgrid.com/national-grid-ventures 

H₂APPLICATIONS INNOVATION

New Zealand’s first H₂ blending pilot reaches 10% milestone 

Firstgas, part of Clarus, together with GasNet, Nova Energy, Powerco and Vector, has reached a key milestone in New Zealand’s first H₂ blending pilot. Fourteen households in Te Horo, on the Kāpiti Coast, are now receiving a gas blend containing 10% H₂ by volume, (which translates to 3% by energy delivered), through the existing gas distribution network. H₂ blending involves mixing H₂ gas into the existing natural gas supply and is a way to test the pipeline infrastructure and gas appliances already in place. 

H₂ is recognized internationally as a potentially renewable gas option that can be stored and transported at large scale. This could make it an ideal complement to solar and wind generation and a valuable tool for helping hard-to-electrify sectors (e.g., high-heat industries, heavy transport, those already using H₂ as a feedstock) to decarbonize. 

More than 5 yrs of preparation and planning have gone into ensuring the pilot can be delivered successfully, with close monitoring at every stage. The project team has worked closely with WorkSafe New Zealand’s Energy Safety team. A H₂ blend display home has also been established in Te Horo, with appliances using the blended gas for cooking and heating demonstrating how existing assets perform during the pilot. 

H₂ blending is already happening safely in countries including the UK, the U.S., Canada, Japan and Australia. In Markham, Ontario, for example, energy company Enbridge is blending up to 5% H₂ into its natural gas network that serves > 3,600 customers, including manufacturing plants, municipal buildings and institutional facilities. 

For more information, visit: https://firstgas.co.nz/our-network 

Swagelok announces two new components for H₂ refueling stations 

Swagelok has announced two new components engineered for safe and efficient operation in H₂ refueling stations. The Swagelok ramp regulator provides controlled pressure during refueling, while the Swagelok FK series H₂ check valve delivers unidirectional flow and shut-off of small-molecule gases, preventing reverse flow. 

In the transportation marketplace, H₂ must be stored at pressures in excess of 700 bar, and the rapid thermal and pressure changes at refueling stations can impact system integrity. The Swagelok ramp regulator serves applications in accordance with SAE J2601—the worldwide standard for H₂ refueling stations—and features a maximum allowable working pressure (MAWP) of 1,050 bar inlet and 875 bar outlet. Its operating temperature range is –40° to 185°F (–40° to 85°C), and it can reach a 120 g/sec H₂ tank fill rate. An optional proportional-integral-derivative (PID) control unit will communicate with the dispenser to reach the required pressure control profile. 

The Swagelok FK series H₂ check valve also features a MAWP of 1,050 bar and handles a temperature range of –40° to 185°F (–40° to 85°C). With a high flow coefficient, all-metal body seal, and a spring that is isolated from the flow path to increase its service life, it has passed third-party H₂ testing per the International Organization for Standardization (ISO)-19880-3 and effectively prevents reverse flow when the differential drops below the fixed cracking pressure of < 2 bar. Swagelok's FK technology can be installed up to five times faster than cone and thread fittings, reducing installation time, assembly and maintenance costs. 

The Swagelok ramp regulator and FK series H₂ check valve are available now. Swagelok also provides materials science expertise, engineering assistance and components such as fittings designed explicitly for H₂ containment. 

For more information, visit: https://products.swagelok.com/en/ 

Colruyt Group and VDL strengthen cooperation in H2Haul project with test of 350 bar H₂ trucks 

Colruyt Group and VDL Enabling Transport Solutions (VDL ETS) are taking the next step in making truck transport more sustainable with the deployment of 350-bar H₂ trucks within the European H2Haul research and development (R&D) project. As a dedicated end user, Colruyt Group is intensively testing the vehicles in its daily logistics operations, with the aim of demonstrating the practical applicability of H₂ technology in the truck transport sector. 

The H2Haul project is co-funded by the European Union and aims to accelerate the introduction of H₂ trucks in Europe. The collaboration between Colruyt Group, VDL ETS and other partners underlines the importance of cross-sectoral innovation to realize the transition to sustainable mobility. 

The trucks being tested by the Belgian retail group are equipped with a series of technological innovations. For example, the fuel cell was developed by OPmobility in cooperation with VDL ETS. The H₂ storage capacity is 40 kilograms (kg), divided over seven lightweight carbon fiber tanks of 241 liters each, at a pressure of 350 bar. This configuration is fully compatible with a standard e-truck with day cab and trailer without exceeding the legal maximum length of 16.5 m. 

The vehicle also features a 210-kilowatt hours (kWh) battery pack and supports a maximum combined weight of 44 t and is being tested in both urban and rural environments. Thanks to the combination of H₂ and battery technology, the range is currently around 450 km—completely emissions-free. 

One H₂ truck has been operational since the end of May, and the second is expected soon and will also be deployed within Colruyt Group's logistics planning. The deployment in real working conditions provides valuable insights for the further development of H₂ drives in heavy-duty applications. 

For more information, visit: https://www.colruytgroup.com/en 

Swiss Steel Group develops solutions to replace natural gas in thermal processes with clean H₂ 

As part of the EU-funded HYDREAMS project, Swiss Steel Group is developing solutions to replace natural gas in thermal processes with clean H₂—without compromising quality, safety or efficiency. Swiss Steel Group is testing different furnace and burner systems, analyzing material properties and creating practical concepts. The first results are promising: In pilot trials with 13 steel grades, no negative impacts on structure or composition were observed. 

For more information, visit: https://swisssteel-group.com/en/products 

H₂ STORAGE AND TRANSPORTATION APPLICATIONS 

Washington State University researchers develop improved liquid H₂ (LH₂) storage tank 

Washington State University (WSU) (U.S.) researchers have developed a mathematical model and a set of recommendations to improve LH₂ storage tank operations that could someday make H₂ a more viable alternative for powering vehicles and other industrial processes. The researchers used real-world tank data to identify operational regimes in which H₂ boils off and is lost, which can be as much as 25% of the H₂ delivered to storage tanks. 

H₂-powered vehicles are an alternative to gasoline or diesel-powered combustion engines because they do not emit harmful greenhouse gases. They are particularly appealing for heavy machinery, such as forklifts or trucking, where electric vehicles require too many batteries. One company, Plug Power, operates about 250 LH₂ tanks that power 70,000 H₂-powered forklifts around the world, moving approximately 30% of groceries in the U.S. 

However, storing and transporting H₂ is a major challenge for the industry. LH₂ is the most convenient form of H₂ for most industrial uses, but keeping it liquid means it must be stored at extremely low temperatures. Any time the H₂ encounters normal air temperatures, it boils off very quickly. To keep the H₂ liquid and move it in and out of tanks, a large number of structural elements and mechanisms are employed, such as insulating shells, pressure valves, fluid circuits and pumps to minimize boil-off losses. 

One area where significant loss occurs is when H₂ is being transferred. In their work, the WSU research team developed a theoretical model for real-world tank performance and verified it using data from a fleet of Plug Power’s in-service tanks. The researchers showed that changes in LH₂ tank operations can yield significant boil-off loss reductions, and that it is possible to achieve zero boil-off with additional system modifications. For instance, they showed that changing the pressure limits when the relief valves are activated can decrease H₂ loss by ~26%. 

Previously, more involved models have taken days to run, required a supercomputer and could only simulate the tank’s operations for a few hours. WSU’s new simplified model calibrated against real-world test data can simulate hundreds of hours of operation in minutes. 

The researchers are continuing to work with Plug Power as they look at ways to implement their recommendations for LH₂ tanks. They also want to refine their model to better understand transfer operations, pumps and other devices in the H₂ systems. The researchers are doing additional studies for the Federal Aviation Administration, evaluating and modeling the storage of LH₂ at airports. 

For more information, visit: https://wsu.edu/research/ 

Carbon280 launches $16-MM pilot plant demonstrating H₂ storage breakthrough 

Carbon280 has launched its Hydrilyte Technology Pilot Plant in Kwinana, Western Australia. The company raised > $16 MM to accelerate its innovative LH₂ storage solution, Hydrilyte. The pilot and laboratory facilities were funded through a $10.6-MM seed investment led by Woodside Energy, with support from UK-based renewable energy company Hive Energy and a Singaporean family office, alongside an estimated $5.5 MM in R&D rebates from the Australian Government. 

Australia’s H₂ ambitions face growing headwinds, with rising costs, technical complexity and a number of high-profile projects stalled or cancelled. Carbon280’s multi-patented Hydrilyte technology addresses a major bottleneck in the H₂ supply chain, enabling H₂ to be stored safely at ambient temperature and pressure. This makes the storage and transport of H₂ safer, more efficient and more economically viable. 

The Hydrilyte Technology Pilot Plant—a 100-kW TRL6 prototype—will prove the Hydrilyte technology at an industrially relevant scale, delivering critical performance data for partners and investors. A successful outcome will validate Carbon280’s technology, reducing the cost for existing H₂ users, improving the economics and speed the implementation of future projects, including production of green iron, synthetic aviation fuels and methanol. 

Hydrilyte’s ability to separate H₂ from helium and store the H₂ ready for transport gives it the potential to advance natural H₂ projects in Australia and globally. Natural H₂ is mixed with other gasses that must be separated. Helium is one of these gasses and very hard to separate from H₂ because of their similar molecular size. Hydrilyte enables separation and storage, ready for transport, in a single step, facilitating the monetization of H₂ and helium for natural H₂ developers. 

As a safe, pumpable liquid, the H₂-containing Hydrilyte can be stored and transported using existing liquid fuels infrastructure, including pipelines, tankers and ships. More broadly, the technology has the potential to deliver a H₂ transportation method that costs less, and is inherently safe, energy efficient and ultra-scalable. 

For more information, visit: https://carbon280.com/hydrilyte-technology-pilot-update-controls-container-and-htp-reactor/ H₂T