Reducing Environmental Impacts of Water Electrolysis Systems by Reuse and Recycling: Life Cycle Assessment of a 5 MW Alkaline Water Electrolysis Plant

Annika C. Hoppe () and Christine Minke
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Annika C. Hoppe: Department of Circular Economy Systems, Institute of Energy Process Engineering and Fuel Technology, Clausthal University of Technology, D-38678 Clausthal-Zellerfeld, Germany
Christine Minke: Department of Circular Economy Systems, Institute of Energy Process Engineering and Fuel Technology, Clausthal University of Technology, D-38678 Clausthal-Zellerfeld, Germany

Energies, 2025, vol. 18, issue 4, 1-16

Abstract: The circular economy offers a vital avenue for sustainable development by optimizing resource utilization through reusing and recycling materials. This study focuses on the lifecycle assessment (LCA) of a 5 MW alkaline water electrolysis (AWE) system, emphasizing end-of-life (EoL) strategies, material recovery, and their environmental implications. Focusing on the recycling and reuse of critical materials—including stainless steel and nickel—we argue that enhancing material efficiency in AWE systems can lead to significant reductions in global warming potential (GWP). Our LCA reveals that manufacturing an AWE system from recycled materials results in a 50% decrease in GWP compared to virgin materials. Despite the operational focus of previous studies, our research uniquely incorporates comprehensive EoL considerations, assessing realistic recycling scenarios that highlight potential material recovery and component reuse after the system’s 20-year lifespan. Notably, 77% of materials in the AWE system can be recycled or reused, though the substantial environmental impacts of certain components, particularly the inverter and nickel, necessitate ongoing research and improved recycling technologies. This study underscores the critical role of systematic recycling and the strategic selection of materials to enhance the sustainability profile of hydrogen production technologies. By bridging the gap between operational efficiency and EoL management in AWE systems, our findings contribute to the broader aim of advancing circular economy principles in clean energy transitions. Ultimately, the research emphasizes the need for integrating innovative recycling methods and material reuse strategies to lower carbon footprints and enhance resource security, aligning with sustainable industrial practices and future energy demands.

Keywords: LCA; circular economy; hydrogen; water electrolysis; resource efficiency; recycling strategies (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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