University of São Paulo (USP) Tests First Renewable Hydrogen Plant Based on Ethanol

(Agência FAPESP*) The University of São Paulo (USP) is testing the world’s first experimental station dedicated to the production of renewable hydrogen from ethanol. The project, carried out by the Research Center for Greenhouse Gas Innovation (RCGI), represents a milestone in the search for clean energy solutions and the transition to a low-carbon economy.

The RCGI is an Engineering Research Center (ERC) created by FAPESP and Shell at the Engineering School of USP.

With an investment of BRL 50 million, the station is located on USP’s main campus in São Paulo city, and is part of a research and development project involving major companies and institutions such as Shell Brasil, Raízen, Hytron (now part of the Neuman & Esser Group), the Technology Center for the Chemical and Textile Industry (SENAI CETIQT) and USP itself, through the RCGI, as well as Toyota, Hyundai, Marcopolo and the São Paulo Metropolitan Urban Transport Company (EMTU). The technology developed aims to demonstrate the viability of ethanol as a vector for the production of sustainable hydrogen, taking advantage of the infrastructure that already exists in the country.

The pilot plant has the capacity to produce 100 kilos of hydrogen per day, which will be used to fuel three buses and two light vehicles, among others. The hydrogen produced will be tested in USP public transport buses and in the Toyota Mirai and Hyundai Nexo vehicles, both of which run on hydrogen.

At this stage, the conversion rate of ethanol to hydrogen and the fuel consumption and efficiency rates of the vehicles will be evaluated. “We’re promoting a revolution in the energy matrix by demonstrating that it’s possible to produce sustainable hydrogen from ethanol with great logistical efficiency,” explains Julio Meneghini, scientific director of the RCGI. “Brazil has unique conditions for this development, given our already consolidated ethanol infrastructure. This opens up opportunities for industrial decarbonization in sectors with high emissions, such as steel and cement, as well as in the chemical and petrochemical sectors, fertilizer production and large-scale freight and passenger transportation.”

Hydrogen production in this pilot plant takes place through the steam reforming of ethanol, a chemical process in which ethanol reacts with water at high temperatures, releasing hydrogen. This method stands out for its efficiency and the possibility of reducing carbon emissions, since the CO2 released in the process is biogenic, i.e. it can be offset in the sugarcane cultivation cycle.

The implementation of the test station paves the way for progress in sustainable mobility. Aircraft, truck and bus manufacturers can directly benefit from the initiative by having access to an important and sustainable source of hydrogen for the development of fuel cell technologies.

“Promoting this technology can bring enormous benefits to Brazilian industry. The availability of hydrogen on a large scale is essential to enable advances on a number of fronts, from mobility to the production of sustainable fertilizers,” Meneghini points out.

During a visit to the plant on February 19th, São Paulo State Governor Tarcísio de Freitas highlighted the importance of the initiative to the state’s economy and its potential for expansion.

“The Research Center for Greenhouse Gas Innovation at the University of São Paulo represents one of the forces that allow our state to lead the energy transition in Brazil: scientific research. In addition, we have water, the largest and best infrastructure in the country, and a qualified workforce, all of which qualify us to be partners in the production of clean, renewable energy for other states and even abroad. We’re taking advantage of the potential of sugarcane to develop solutions that will transform and impact entire industries, such as transportation,” he said.

In his speech, the Governor gave thanks for the support of FAPESP, which “has been doing fundamental work.” He also thanked the other partners in the project, including USP, Shell and Raízen. “It’s a partnership that makes us excited. If I’m excited, I imagine you are too. Because it’s not easy to go from lab scale to prototype to pre-industrial scale. And you’re taking these steps. Brazilian science is once again giving an answer. We’ve already left the climate change phase and entered the climate emergency. So we need speed to find solutions. And Brazilian science always gives us solutions,” he said.

Tarcísio de Freitas pointed to the energy transition and the knowledge economy as the two pillars of development. He also highlighted the partnership with FAPESP and USP to create a biotechnology center and a startup incubator focused on artificial intelligence.

It is hoped that the results obtained with the pilot plant will provide data that can guide future studies on its application on a larger scale. “Our goal is to demonstrate the potential of this solution and generate technical-scientific knowledge about its viability, taking advantage of the ethanol infrastructure to enable the production and distribution of renewable hydrogen,” Meneghini explains.

The rector of USP, Carlos Gilberto Carlotti Junior, also celebrated the development of the tests and stressed the importance of the project: “The role of universities is to develop technologies that don’t exist yet, so that Brazil can make an energy transition and thus position itself as a first-world country. If we can offer cheaper energy with a smaller carbon footprint, we’ll certainly be a world leader. For this to happen, it’s essential that universities generate knowledge and that companies believe in and invest in the industrialization of these ideas. This is how great technological advances began: with academic research transformed into innovation for society.”

The progress of USP’s experimental plant marks a significant step towards the production of sustainable hydrogen in Brazil. Julio Meneghini predicts that “the technology will help consolidate the country as one of the world’s leaders in clean energy production, reducing dependence on fossil fuels and boosting various economic sectors in a sustainable way.”