Comprehensive energy balance analysis and techno-economic evaluation of static hydrogen carbon savings for an industrial dual-fuel combustor used in food manufacturing

Energy balance and techno-economic emission analysis of dual-fuel industrial fryer • Energy balance of hydrogen substitution in an industrial dual-fuel fryer is presented, assessing efficiency and emissions reductions. • Techno-economic evaluation of industrial hydrogen integration with green supply, covering CAPEX, OPEX, carbon tax, payback. • Results show hydrogen blending up to 100% is feasible with burner replacement only, enabling emissions cuts up to 97.3%. • Rapid payback is possible with minimal CAPEX, aided by lower carbon taxes despite higher near-term hydrogen costs. • Pipeline hydrogen delivery gives greatest carbon and economic gains, while long-distance transport reduces effectiveness. Industry contributes around a quarter of the United Kingdom’s greenhouse gas emissions, and the UK Government has set ambitious net-zero targets, including establishing the first net-zero industrial cluster by 2040. Decarbonizing heavy industry will rely on technologies such as carbon capture and storage and the transition to low-emission fuels like hydrogen, though its adoption is hindered by uncertainties around feasibility, cost, and supply. This study proposes a dual-fuel strategy and presents a comprehensive energy balance, emissions assessment, and techno-economic analysis of hydrogen–natural gas blends in an industrial fryer. A baseline natural-gas energy profile is developed, followed by evaluation of hydrogen substitution up to 100 %. The analysis incorporates capital and operational costs, including hydrogen transport, and relevant UK policy incentives for low-emission combustion. Results confirm technical feasibility and show that full hydrogen substitution via pipeline or local seaport delivery can cut CO 2 emissions by up to 97 % while reducing carbon-tax liabilities and operating costs. However, large-distance truck transport and reduced carbon-tax pressures significantly erode these benefits, underscoring the need for optimized supply chains and supportive policy. Operational costs remain lower than with natural gas, but fixed on-site hydrogen storage is not financially viable due to long payback periods. Overall, hydrogen is shown to be a promising low-emission industrial fuel, provided favorable policy and infrastructure conditions are in place.