Low-Carbon Hydrogen Production in the U.S.

The last year has seen many government and stakeholders embrace the strengths of hydrogen to reduce carbon emissions. In order to continue to develop the use of hydrogen, increasing production of hydrogen through various low-carbon methods will be critical. Across the United States (U.S.), the industry is expanding hydrogen production capacity today, demonstrating the range of ways to utilize the country’s existing resources.

Electrolysis

According to the Department of Energy (DOE), there were 172 megawatts (MW) of electrolyzers currently operating or planned for operation in the U.S. in June of 2021, with additional production using other pathways being explored across the country.

A Department of Energy map showing electrolyzer locations in the United States. (Source: Department of Energy)

FCHEA has several members with electrolyzer products.  One company actively expanding hydrogen production capabilities in the U.S. is FCHEA member Plug Power. The company already offers products that utilize hydrogen, but in 2021, Plug Power announced an expansion of green hydrogen plants across the country. Through the year, the company began construction of sites in New York, Pennsylvania, and Georgia, and announced an additional site in California for the next stage of facilities. 

NY Governor Kathy Hochul and Plug Power CEO Andy Marsh at the groundbreaking in NY. (Source: Plug Power)

FCHEA member Bloom Energy, expanding its portfolio to include solid oxide electrolyzer systems, announced in December 2021 that it was joining SoCalGas’s existing hydrogen blending project at the California Institute of Technology in Pasadena, where Bloom will provide electrolyzers to generate hydrogen to blend into existing natural gas pipelines.

One source of power for electrolysis that is carbon-free utilizes spare capacity from hydropower facilities. FCHEA member Cummins is working on one such project, in Douglas County, Washington. Located at a dam built in the 1960s, Cummins is constructing a 5 MW electrolyzer that will convert the spare electricity the facility produces into hydrogen for a variety of uses, while reducing strain and maintenance on the dam’s facilities. In addition to producing hydrogen, Douglas County PUD will deploy fuel cells from FCHEA member GenCell for hydrogen-fueled backup power at the facility itself.

Wells Dam in Douglas County, Washington, site of the Cummins electrolyzer. (Source: Seattle Times)

Alongside hydropower, electrolysis utilizing electricity from nuclear power facilities can provide carbon-free hydrogen from existing resources. FCHEA member Nel Hydrogen is part of a DOE sponsored project, through the H2@Scale initiative, demonstrating the opportunity for partnering nuclear power plants with hydrogen production as a method of balancing variable electricity demand. Nel provided a 1.25 MW electrolyzer that will initially provide hydrogen for usage directly at the facility, while also providing research opportunities for the expansion of such partnerships.

Pyrolysis

Methane pyrolysis is a method for producing hydrogen from natural gas that does not result in carbon emissions, as the process results in hydrogen and carbon black, which can be used to create rubber and plastics. FCHEA member Monolith built and operates a commercial-scale pyrolysis plant in Nebraska, for use in ammonia production. In December 2021, Monolith received conditional approval for a $1.04 billion loan from DOE’s Loan Program Office to expand its existing facility.

SMR with CCUS

Another FCHEA member, Air Products, is also working to expand low-carbon emission hydrogen production in the U. S., with the company in October 2021 announcing a $4.5 billion complex that will be built in Ascension Parish, Louisiana, opening in 2026. Once completed, the facility will produce over 750 million cubic feet of hydrogen per day, utilizing carbon capture facilities to prevent emissions and permanently sequester the carbon dioxide.

SMR with RNG

Air Liquide, another FCHEA member, is introducing new methods of reducing carbon emissions in the reformation process in addition to carbon capture. The company is constructing a hydrogen production facility outside Las Vegas, Nevada, that will utilize renewable natural gas as a feedstock when it enters operations in 2022. Utilizing these alternate sources of gas reduces the emissions footprint of the facility alongside carbon capture technology.

Hyzon Motors, an additional FCHEA member, partnered with Raven SR to produce hydrogen from waste gases. The partners initial project is planned to open in 2022 in Northern California and will produce 2,000 metric tons of hydrogen annually, for use as a transportation fuel. 

There are a variety of ways to produce low-carbon hydrogen today and as the examples shared above show, FCHEA members are actively growing production volumes across the U.S. With a growing demand for hydrogen for use across a range of sectors, a corresponding and continuing growth in low-carbon hydrogen production is required to meet the U.S.’ needs.