Techno-economic and environmental analysis of the green hydrogen production processes via biogas-based sorption-enhanced reforming

This study investigates the potential of biogas sorption-enhanced reforming for the production of low-carbon hydrogen. A 1D dynamic model of a bubbling fluidized-bed sorption-enhanced reforming reactor was developed in MATLAB/Simulink and validated using literature data for hydrogen yield and methane conversion. The validated reactor model was integrated into CHEMCAD process simulations to assess 100 MW th industrial-scale hydrogen production systems. Four reforming-based configurations were evaluated using techno-economic and environmental assessment, while two additional electrolysis pathways were considered for environmental analysis only. The results show that sorption-enhanced reforming using biogas achieves a carbon capture rate of 99.44% and near-zero process emissions (2.99 kg CO 2 /MWh). The configuration demonstrates a cumulative energy efficiency of 60.38% and produces surplus electricity of 9.13 MW e . From an economic perspective, the levelized cost of hydrogen was estimated at 67.12 €/kWh, with a CO 2 avoidance cost of 38.59 €/t, indicating competitiveness under current European carbon pricing conditions. Life cycle assessment further reveals a net-negative global warming potential of −8.06 kg CO 2 eq./kg H2 produced , driven by the combined effects of biogenic feedstock utilization and high CO 2 capture efficiency. Overall, the results demonstrate that biogas-based sorption-enhanced reforming represents a promising pathway for large-scale production of low-carbon hydrogen, combining high capture performance with strong environmental benefits. • Development of a dynamic reactor model for biogas-based green hydrogen production. • Techno-economic and environmental assessment of industrial-scale hydrogen plants. • Sorption-enhanced reforming achieves 99.44% carbon dioxide capture from biogas. • Biogas-fed sorption-enhanced reforming shows negative global warming potential.