Experimental Investigation of Green Hydrogen Integration into Industrial Thermal Systems for Sustainable and Low Carbon  Manufacturing Applications

Dwi Feriyanto; Agus Wantoro; Deny Prasetyo; Very Dwi Setiawan; Faizal Riza

doi:10.61132/ijiime.v1i2.397

Authors

Dwi Feriyanto Universitas Aisyah Pringsewu
Agus Wantoro Universitas Teknokrat Indonesia
Deny Prasetyo Universitas Sugeng Hartono
Very Dwi Setiawan Universitas Pignatelli Triputra
Faizal Riza Institut Teknologi Budi Utomo

DOI:

https://doi.org/10.61132/ijiime.v1i2.397

Keywords:

CO₂ Emissions, Combustion System Optimization, Hydrogen Blending, NOx Emissions, Thermal Efficiency

Abstract

Background: The global energy transition requires low-carbon solutions that can be integrated into existing thermal systems without drastic infrastructure changes. Hydrogen blending in conventional combustion systems has emerged as a promising pathway to reduce carbon emissions while maintaining operational flexibility. Objective: This study aims to experimentally evaluate the effect of hydrogen blending ratios (0–100% by volume) on thermal efficiency, CO₂ emissions, and NOx emissions, and to determine the optimal blending range based on technical and economic feasibility. Methods: An experimental thermal system prototype was developed and tested under controlled conditions with three repetitions per operating point. Performance parameters included combustion temperature, fuel consumption rate, and thermal efficiency, while emissions of CO₂ and NOx were measured using a calibrated gas analyzer. Data were analyzed using descriptive statistics, one-way ANOVA at a 0.05 significance level, confidence interval estimation, and linear regression to examine the relationship between hydrogen fraction and emission reduction. Results: The findings indicate that increasing hydrogen fraction significantly improves thermal efficiency, reaching 87.5% at 100% hydrogen, while CO₂ emissions decrease linearly to zero. However, NOx emissions increase with higher hydrogen content due to elevated combustion temperatures. Statistical analysis confirms that hydrogen ratio has a significant effect on efficiency and emissions, with a strong linear correlation between hydrogen fraction and CO₂ reduction. A blending range of 40–60% hydrogen provides the most balanced performance in terms of efficiency improvement, emission reduction, and cost feasibility.

References

Alipour, F., Zandi Lak, S., & Rahimpour, M. R. (2024). Economic challenges of moving beyond fossil fuels. In Encyclopedia of Renewable Energy, Sustainability and the Environment (Vol. 1, pp. 131–142). https://doi.org/10.1016/B978-0-323-93940-9.00249-8

Chen, J., Dwarka, V., & Vuik, C. (2024). A matrix-free parallel two-level deflation preconditioner for two-dimensional heterogeneous Helmholtz problems. Journal of Computational Physics, 514, 113264. https://doi.org/10.1016/j.jcp.2024.113264

Chen, S., Chen, J., Chen, H., Chen, W., Lin, X., & Chen, G. (2021). Analysis on energy demands and load characteristics of industrial parks dominated integrated energy systems. 2021 11th International Conference on Power and Energy Systems (ICPES 2021), 801–807. https://doi.org/10.1109/ICPES53652.2021.9683824

Chen, Y.-Y., Huo, J., Ding, T.-Y., & Gao, Y. (2024). Survey of Meta-Reinforcement Learning Research. Journal of Software, 35(4), 1618–1650. https://doi.org/10.13328/j.cnki.jos.007011

Cormos, A.-M., Dragan, S., Petrescu, L., Sandu, V., & Cormos, C.-C. (2020). Techno-economic and environmental evaluations of decarbonized fossil-intensive industrial processes by reactive absorption and adsorption CO2 capture systems. Energies, 13(5), 1268. https://doi.org/10.3390/en13051268

Esmaeely, S. N., Finneran, S., Cederlof, D. J. H., Cummings, A., & Gersen, S. (2024). Feasibility journey – feasibility of repurposing existing natural gas network to transport hydrogen – natural gas blends at the distribution level. AMPP Annual Conference and Expo 2024.

Giacomazzi, E., Troiani, G., Di Nardo, A., Calchetti, G., Cecere, D., Messina, G., & Carpenella, S. (2023). Hydrogen combustion: Features and barriers to its exploitation in the energy transition. Energies, 16(20), 7174. https://doi.org/10.3390/en16207174

Guidi, G., Violante, A. C., & De Iuliis, S. (2023). Environmental impact of electricity generation technologies: A comparison between conventional, nuclear, and renewable technologies. Energies, 16(23), 7847. https://doi.org/10.3390/en16237847

Harichandan, S., & Kar, S. K. (2024). An empirical study on technology readiness level of industries to use green hydrogen in India: Role of policy interventions. International Journal of Energy Sector Management, 18(6), 2115–2140. https://doi.org/10.1108/IJESM-01-2024-0011

Ionescu, C., Tutica, D., Patrascu, R., Dinca, C., & Slavu, N. (2019). Evaluation of the energy efficiency of an industrial consumer in trigeneration mode. E3S Web of Conferences, 85, 1005. https://doi.org/10.1051/e3sconf/20198501005

Islam, A., Alam, T., Sheibley, N., Edmonson, K., Burns, D., & Hernandez, M. (2024). Hydrogen blending in natural gas pipelines: A comprehensive review of material compatibility and safety considerations. International Journal of Hydrogen Energy, 93, 1429–1461. https://doi.org/10.1016/j.ijhydene.2024.10.384

Kaiser, S., Erxleben, K., Rhode, M., & Kannengiesser, T. (2024). Repair welding of in-service hydrogen pipelines—Concepts and challenges. Proceedings of the Biennial International Pipeline Conference (IPC), 3, v003t05a013. https://doi.org/10.1115/IPC2024-133052

Kim, J.-K., Kim, M., Binns, M., Lee, J. H., Cho, H., & Yi, S. C. (2021). Integrated heat and power management of buildings with the energy recovery of a cement plant. Journal of Ceramic Processing Research, 22(6), 722–730. https://doi.org/10.36410/jcpr.2021.22.6.722

Kuwabara, K., Manabe, Y., Mito, S., Yamagiwa, R. E. O., Yamaguchi, T., Yoshihara, S., Miyamoto, S., & Iijima, A. (2023). Effects of hydrocarbon with different ignition properties and hydrogen blended fuels on autoignition and combustion in an IC engine. https://doi.org/10.4271/2023-01-1802

Louvet, F., Abid, M., Charnavel, Y., & Hevin, G. (2017). Comparative study of hydrogen storage in salt caverns. International Gas Research Conference Proceedings, 1, 534–541.

Miro, L., Gasia, J., & Cabeza, L. F. (2016). Thermal energy storage (TES) for industrial waste heat (IWH) recovery: A review. Applied Energy, 179, 284–301. https://doi.org/10.1016/j.apenergy.2016.06.147

Paterlini, L., Casanova, L., Bolzoni, F. M., Ormellese, M., & Re, G. (2024). Compatibility of metallic materials with high pressure gaseous hydrogen: Applicable standards and non-standard tests. Metallurgia Italiana, 115(1), 16–22.

Price, C. R., Nimbalkar, S. U., Thirumaran, K., & Cresko, J. (2023). Smart manufacturing pathways for industrial decarbonization and thermal process intensification. Smart and Sustainable Manufacturing Systems, 7(1), 41–53. https://doi.org/10.1520/SSMS20220027

Raina, N., Chuetor, S., Charoenkool, P., Jiradechakorn, T., Sereenonchai, C., Phojaroen, J., Boonmee, R., Pathak, A. K., & Singh, H. M. (2024). Opportunities and challenges in the production of biofuels from waste biomass. In Waste Valorization for Bioenergy and Bioproducts: Biofuels, Biogas, and Value-Added Products (pp. 23–43). https://doi.org/10.1016/B978-0-443-19171-8.00006-7

Rey, J., Segura, F., & Andujar, J. M. (2023). Green hydrogen: Resources consumption, technological maturity, and regulatory framework. Energies, 16(17), 6222. https://doi.org/10.3390/en16176222

Sebbagh, T., Sahin, M. E., & Beldjaatit, C. (2024). Green hydrogen revolution for a sustainable energy future. Clean Technologies and Environmental Policy, 26(12), 4017–4040. https://doi.org/10.1007/s10098-024-02995-9

Seyitini, L., Belgasim, B., & Enweremadu, C. (2024). An assessment of demand for industrial process heat, viability of solar thermal and sensible heat storage technologies in Zimbabwe. International Journal of Renewable Energy Research, 14(3), 613–624. https://doi.org/10.20508/ijrer.v14i3.14629.g8940

Tchouvelev, A. V. (2016). Hydrogen safety and RCS (Regulations, Codes, and Standards). In Fuel Cells: Data, Facts, and Figures (pp. 369–378). https://doi.org/10.1002/9783527693924.ch36

Wagner, H.-J., & Mathur, J. (2018). Life cycle assessment of a wind farm. In Green Energy and Technology (pp. 89–96). https://doi.org/10.1007/978-3-319-68804-6_8

Wallace, R. L., Cai, Z., Zhang, H., & Guo, C. (2024). Numerical investigations into the comparison of hydrogen and gas mixtures storage within salt caverns. Energy, 311, 133369. https://doi.org/10.1016/j.energy.2024.133369

Weber, P. A., Zhang, N., & Wu, H. (2020). A comparative analysis of personal data protection regulations between the EU and China. https://doi.org/10.1007/s10660-020-09422-3

Wu, D., Sun, B., Luo, Q., Wang, X., & Ge, Y. (2017). Calculations and test measurements of in-cylinder combustion velocity of hydrogen-air mixtures considering the effect of flame instability. https://doi.org/10.4271/2017-01-0780

Zhao, K., Lou, D., Zhang, Y., Fang, L., & Liu, D. (2024). Study on combustion and emission characteristics of hydrogen/air mixtures in a constant volume combustion bomb. Renewable Energy, 237, 121626. https://doi.org/10.1016/j.renene.2024.121626