Green hydrogen: future technology for sustainable energy production!

Green hydrogen: future technology for sustainable energy production!

In an innovative step to promote sustainable energy sources, the ESC Lab at the Brandenburg Technical University Cottbus-Senftenberg has made groundbreaking advances in methane synthesis. The reactors convert green hydrogen and carbon dioxide (CO₂) from industrial processes into synthetic methane, a carbon-neutral energy source with a high calorific value. This technology could make a significant contribution to reducing greenhouse gas emissions.

The methane synthesis reactors work at temperatures of 300 to 350°C and a pressure range of 1 to 10bar. Ni/Al₂O₃ catalysts are used. In order to further optimize the reactors, one-dimensional simulation models are used, whose long computing times provide valuable insights into the process. The ESC Lab is developing a metamodel that predicts the influences of pressure and dilution on methane synthesis. This model is intended to be integrated into Power-to-X applications and digital twins, which could significantly increase the efficiency of the processes.

Development of a metamodel

To train the metamodel, data sets are generated from 5,000 simulations of the reactor model. The varying parameters include gas inlet composition, temperature, pressure, flow rate, reactor length and reaction progress. To develop the prediction models, the scientists use a 6th order polynomial, a feedforward neural network and Gaussian processes. The objective is clear: to create a fast, data-driven prediction model to optimize Power-to-X processes and digital twins.

Over 220,000 simulation points were created for a robust training dataset, enabling accurate modeling. The neural network provides the best predictions for the reactor temperature over the reactor length. It also shows good results in mapping the effect of pressure and dilution on methane content. Gaussian processes prove to be particularly effective for predicting hydrogen. Scientists such as Tim Franken, Monang Vadivala, Saurabh Sharma, Tobias Gloesslein and Fabian Mauß are crucially involved in this research project.

Integration into Power-to-X technologies

The application of the developed technologies in energy storage and conversion is becoming increasingly important. Excess energy from wind power and photovoltaic systems is converted into valuable energy sources as part of sector coupling. A research team working in the Power-to-Methanol project led by Frankfurt-based Dechema is investigating the conversion of hydrogen and CO₂ into methanol using biogas plants. This method could significantly improve flexibility in the electricity sector.

The project has developed two concepts for plants to produce green methanol from green electricity. Technical developments and planning for real plant locations were taken into account. The challenges lie particularly in the location-specific conditions, and the provision of green electricity or hydrogen is of central importance. The synthesis of green methanol with green CO₂, which is produced in the production of bioethanol, is particularly promising.

In a positive summary, the project team and partners recommend further developing the regulatory framework for the production of green methanol from green electricity and green CO₂. A combination of basic research, practical plant engineering and economic analysis has proven to be essential to advance the implementation of these innovative technologies.

The results of this research were recently presented at the 2nd General Meeting of COST Action CYPHER in Krakow in May 2025, which provided the opportunity to highlight the latest advances in methane synthesis and related technologies. The central, ambitious vision is clear: the transformation of the energy sector through innovative Power-to-X technologies for a sustainable future. Further information can be found on the website Brandenburg Technical University, the PTX Alliance and that Power-to-methanol project.