Techno-economic analysis of hydrogen production in the sugarcane industry by steam reforming of ethanol with carbon capture

Renewable hydrogen production is a pivotal technology in transitioning to sustainable energy and is essential for global decarbonisation efforts. This study explores the integration of hydrogen production into sugarcane biorefineries, which have shifted from traditional sugar production to integrated bioenergy hubs. Specifically, steam reforming of ethanol was selected as the process for hydrogen generation. A comprehensive techno-economic analysis was developed to address research gaps and guide future work. A scenario of hydrogen production coupled with carbon capture was analysed, illustrating the potential to reduce the carbon footprint and utilise carbon dioxide for producing chemicals. The minimum selling price for hydrogen was determined to be 4.6 US$/kg for the base case scenario and 4.9 US$/kg for the comparison scenario with carbon capture, positioning it below the current average market price of 7.2 US$/kg. The capital and operating expenditures were determined to be US$ 273.1 million and 157.8 million for a 42,400 t/y hydrogen plant, and integrating carbon capture considering 282,800 t/y of carbon co-product yield was calculated at US$ 344.1 million and US$ 167.8 million, respectively. This dual approach of hydrogen production and carbon capture presents a strategy for implementing low-carbon processes that future biorefineries may consider. The primary impact highlighted by this integration is the enhancement of the sugarcane biorefineries’ value proposition, leveraging undervalued energy sources such as electricity and biogas. This study underscores the economic and environmental benefits of incorporating hydrogen production into sugarcane biorefineries on a large scale, offering a framework for future research and technological development.