Study and Design of Hydrogen Production from Municipal Wastewater Using Microbial Electrolysis Cells: A Case Study of Helwan Wastewater Treatment Plant, Egypt

Hydrogen is emerging as a key pillar of global decarburization strategies due to its high energy density and zero direct emissions, yet most production still depends on fossil-based processes such as steam methane reforming (SMR). This study introduces the first large-scale design and modeling of a microbial electrolysis cell (MEC) system for hydrogen production from municipal wastewater in Egypt, developed for the Helwan Wastewater Treatment Plant (550,000 m³/day, COD ≈ 500 mg/L). The system integrates wastewater treatment with renewable hydrogen generation by utilizing electroactive bacteria to oxidize organic matter under low external voltage (0.2–0.8 V). Modeling results indicate a hydrogen yield of 17.9 tons/day (≈595 MWh/day) with only 456 kWh/day of external energy input and an estimated CO₂ reduction of 65,000 tons per year compared with SMR. A preliminary economic outlook suggests competitive production potential when co-located with existing wastewater infrastructure. Overall, the study demonstrates the technical feasibility, environmental benefits, and economic promise of MECs as a scalable and sustainable pathway for hydrogen production and resource recovery in developing regions.