Techno-economic comparison of ammonia cracking and separation using metal membrane and pressure swing adsorption

Ammonia is a promising hydrogen (H 2 ) carrier, enabling efficient storage and transport. This study presents a comparative techno-economic assessment of two hydrogen separation approaches downstream of ammonia cracking: pressure swing adsorption (PSA), which is commercially established, and metal membrane separation, which remains at an early stage of development. Based on literature data, metal membranes achieve 99 % hydrogen purity, while PSA yields 85 % recovery. Techno economic analysis shows metal membranes consume 7.4 MWh per tonne H 2 , compared to 8.5 MWh per tonne H 2 for PSA. Metal membranes also involve higher material costs and embrittlement risks, while PSA offers lower capital and operating costs. Economic analysis shows metal membranes yield a net present value (NPV) of USD 420 million and internal rate of return (IRR) of 28 %, while PSA achieves USD 410 million (NPV) and 25 % IRR. PSA remains more viable for large scale use, while membranes may suit high purity applications. • Hydrogen (H 2 ) separation using a metal membrane and pressure swing adsorption. • Metal membranes achieve 99 % H 2 purity but face high costs and embrittlement risks. • PSA offers lower CAPEX/OPEX but has a lower H 2 recovery (85 %) and higher energy use. • Metal membranes: NPV $420 M, IRR 28 %; PSA: NPV $410 M, IRR 25 %, lower OPEX. • Metal membranes suit high-purity H 2 , and PSA is better for large-scale production.