Case Study of a Greenfield Blue Hydrogen Plant: A Comparative Analysis of Production Methods

Mohammad Sajjadi and Hussameldin Ibrahim ()
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Mohammad Sajjadi: Clean Energy Technologies Research Institute (CETRI), Process Systems Engineering, Faculty of Engineering and Applied Science, University of Regina, 3737 Wascana Parkway, Regina, SK S4S 0A2, Canada
Hussameldin Ibrahim: Clean Energy Technologies Research Institute (CETRI), Process Systems Engineering, Faculty of Engineering and Applied Science, University of Regina, 3737 Wascana Parkway, Regina, SK S4S 0A2, Canada

Energies, 2025, vol. 18, issue 13, 1-24

Abstract: Blue hydrogen is a key pathway for reducing greenhouse gas emissions while utilizing natural gas with carbon capture and storage (CCS). This study conducts a techno-economic and environmental analysis of a greenfield blue hydrogen plant in Saskatchewan, Canada, integrating both SMR and ATR technologies. Unlike previous studies that focus mainly on production units, this research includes all process and utility systems such as H 2 and CO 2 compression, air separation, refrigeration, co-generation, and gas dehydration. Aspen HYSYS simulations revealed ATR’s energy demand is 10% lower than that of SMR. The hydrogen production cost was USD 3.28/kg for ATR and USD 3.33/kg for SMR, while a separate study estimated a USD 2.2/kg cost for design without utilities, highlighting the impact of indirect costs. Environmental analysis showed ATR’s lower Global Warming Potential (GWP) compared to SMR, reducing its carbon footprint. The results signified the role of utility integration, site conditions, and process selection in optimizing energy efficiency, costs, and sustainability.

Keywords: hydrogen; carbon capture; greenfield plant design; process simulation; TEA (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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