Dual Technical and Environmental Assessment of the Transition from Grey to Green Hydrogen in the Haber–Bosch Process: A Modelling and Simulation Approach

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Original abstract

This work evaluates the transition from grey to green hydrogen in the Haber–Bosch process through a case study of the Fertial ammonia plant. An integrated assessment per ton of NH3 was conducted using coupled process simulation with system-level mass, energy, and emission accounting, which link the electrolyser dynamics with ammonia loop operation under variable renewable conditions. The results show an electrical demand of 8.9 MWh/t NH3 and significant water consumption potential of 27–34 m3/t NH3. Compared with grey ammonia produced via SMR hydrogen (3.65–4.63 t CO2/t NH3), renewable electrolysis reduces total emissions by up to 64% and fossil resource use by approximately 71% (case of 100% PV), depending on electricity carbon intensity. While renewable electricity enables ammonia decarbonization, high water consumption potential represents a challenge. Additionally, hydrogen purity fluctuations and intermittent electrolyser output affect loop conversion and process stability, highlighting the need for heat integration and storage strategies to maintain steady operation.

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