Comparative techno‐economic and environmental study of hybrid and pure adsorption for carbon capture in blue hydrogen

Abstract Blue hydrogen offers a promising solution for mitigating global warming. Accordingly, improving carbon capture in blue H 2 plant designs becomes crucial. This study assesses and compares the viability of technologies for 100 and 400 tonnes‐per‐day plants, considering technical, environmental, and economic aspects using Aspen HYSYS and ReCiPe methodology for process simulation and life cycle assessment respectively. The hybrid absorption/adsorption system demonstrated superior long‐term profitability and higher net present value, despite its higher capital costs. In contrast, the adsorption‐only system resulted in a shorter payback period and lower equivalent emissions. The cost of hydrogen production was $2.20/kg for the former and $1.80/kg for the latter, with a slight difference in rate of return. Additionally, sensitivity analysis revealed the impact of natural gas costs, H 2 and CO 2 selling prices, and zeolite costs on profitability. Also, scale‐up showed that a plant with a larger capacity is more profitable.