Integrated safety and economic assessment of blue hydrogen production through modelling and simulation

Integrated safety and economic assessment of blue hydrogen production through modelling and simulation | Authorea try { document.documentElement.classList.add('js'); } catch (e) { } var _gaq = _gaq || []; _gaq.push(['_setAccount', 'G-8VDV14Y67G']); _gaq.push(['_trackPageview']); (function() { var ga = document.createElement('script'); ga.type = 'text/javascript'; ga.async = true; ga.src = ('https:' == document.location.protocol ? 'https://ssl' : 'http://www') + '.google-analytics.com/ga.js'; var s = document.getElementsByTagName('script')[0]; s.parentNode.insertBefore(ga, s); })(); Skip to main content Preprints Collections Wiley Open Research IET Open Research Ecological Society of Japan All Collections About About Authorea FAQs Contact Us Quick Search anywhere Search for preprint articles, keywords, etc. Search Search ADVANCED SEARCH SCROLL This is a preprint and has not been peer reviewed. Data may be preliminary. 1 December 2025 V1 Latest version Share on Integrated safety and economic assessment of blue hydrogen production through modelling and simulation Authors : Yiming Li , Chunkun Tian , Alasdair Campbell N , and Yaxian Li 0009-0001-1221-7990 [email protected] Authors Info & Affiliations https://doi.org/10.22541/au.176457622.28276858/v1 145 views 82 downloads Contents Abstract Supplementary Material Information & Authors Metrics & Citations View Options References Figures Tables Media Share Abstract Global demand for hydrogen was about 100 million tonnes in 2024. Driven by net-zero emissions scenarios, this demand is growing rapidly. Projections from the International Energy Agency (IEA) indicate that global hydrogen demand is expected to exceed 200 million tonnes/year by 2030. The commercial deployment of blue and green hydrogen will be the main contributor to this demand growth. In comparison to green hydrogen production, blue hydrogen production (BHP) currently holds a commercial deployment advantage, because it is an improvement upon existing hydrogen production technologies rather than a complete redesign. However, the commercial deployment of BHP still faces cost and safety challenges. This study proposes a weighted risk index (WRI) method to assess the overall process risk of BHP process and considers the impact of changes in operating temperature and pressure on overall process risk. Compared with the Dow’s fire and explosion index (F&EI), WRI is more sensitive to changes in operating conditions because it balances the influence of different risk factors. In addition, an integrated model is developed to investigate the relationship between potential process safety improvements and economic benefits. The results of integrating risk and economics analysis showed that the recommended operating temperature should be between 800-1000 ℃. The operating pressures above 30 bara should be avoided. Furthermore, an additional cooling unit located between the main-reformer and the water gas shift (WGS) helps avoid hazards caused by high operating temperatures. Supplementary Material File (manuscript.docx) Download 424.52 KB Information & Authors Information Version history V1 Version 1 01 December 2025 Copyright This work is licensed under a Non Exclusive No Reuse License. Keywords blue hydrogen integrated safety and economic assessment post-combustion carbon capture steam methane reforming weighted risk index Authors Affiliations Yiming Li Hefei Normal University View all articles by this author Chunkun Tian The University of Sheffield Department of Chemical and Biological Engineering View all articles by this author Alasdair Campbell N The University of Sheffield Department of Chemical and Biological Engineering View all articles by this author Yaxian Li 0009-0001-1221-7990 [email protected] Anhui Medical University View all articles by this author Metrics & Citations Metrics Article Usage 145 views 82 downloads .FvxKWukQNSOunydq8rnd { width: 100px; } Citations Download citation Yiming Li, Chunkun Tian, Alasdair Campbell N, et al. Integrated safety and economic assessment of blue hydrogen production through modelling and simulation. Authorea . 01 December 2025. 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