Green hydrogen extraction from natural gas transmission grids using hybrid membrane and PSA processes optimized via bayesian techniques

Green hydrogen (H₂) is a leading enabler for the decarbonization of hard-to-abate industries where electrification is either uneconomical or infeasible. Establishing an adequate and cost-effective infrastructure for hydrogen distribution remains one of the primary barriers to its widespread adoption. A promising short-term solution to this challenge involves H₂ storage and co-transportation via existing gas grids. For H₂ extraction from distribution gas grids, standalone pressure swing adsorption systems are considered the most viable option, whereas a hybrid process is suggested in the literature for transmission gas networks. This article presents a comprehensive techno-economic model for the proposed hybrid process, developed using an integrated platform based on Aspen Adsorption and Aspen Custom Modeler. The system consists of a single-stage hollow fiber Matrimid membrane module, followed by a 4-bed adsorption process operating in 8 sequential steps to meet H₂ market purity requirements with an acceptable recovery rate. Since the performances of these two separation modules, as an integrated system, significantly influence each other, the study identifies a unique opportunity to minimize separation costs through process optimization. To reduce computational time, a cyclic steady-state approach was employed to simulate the PSA process. Bayesian optimization, facilitated by the integration of Python with Aspen Adsorption, was used to efficiently identify the optimal solution with a minimal number of objective function evaluations. The levelized cost of H₂ separation (99.0 % purity at 10 bar) from natural gas containing 10 % H₂ at pressures of 35 bar and 60 bar is estimated to be 2.7310 and, $2.5116/kg-H₂, respectively. These estimates correspond to a scenario with 10 identical trains, each handling a feed flowrate of 200 kmol/hr. Increasing the number of trains keeps the cost contribution of PSA constant; however, the total cost decreases as the compression fixed cost is distributed across more trains.