Researchers at the MIT Energy Initiative have developed the Hydrogen Carrier Analysis Tool (HyCAT), an open-source tool that helps decision-makers evaluate costs and carbon emissions associated with different hydrogen-transportation options.
Study: Hydrogen carrier analysis tool (HyCAT): Integrated economics and emissions assessment for long distance hydrogen transportation. Image Credit: Deemerwha studio/Shutterstock.com
Multiple hydrogen carriers and shipping pathways were compared under different operating conditions. The findings, published in Fuel, point to the importance of location-specific analysis for developing cost-effective and low-carbon hydrogen supply chains.
Overcoming the Transport Challenge for Clean Hydrogen
Hydrogen has emerged as a promising clean energy carrier for reducing carbon emissions, capable of generating electricity in fuel cells and replacing fossil fuels in industries such as steel, cement, and chemicals.
However, producing low-carbon hydrogen is only part of the solution; it must also be transported safely, efficiently, and at a reasonable cost.
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Hydrogen’s physical properties make its transportation difficult. It has a very low energy density by volume, so large quantities are needed to deliver useful amounts of energy, and there is a higher risk of leaks in storage systems than with conventional fuels because of the small size of hydrogen molecules.
Most hydrogen research has focused on developing cleaner production methods, while hydrogen transportation has received far less attention. Existing studies often reach different conclusions because transportation costs and greenhouse gas emissions depend on factors such as shipping distance, electricity prices, infrastructure, and regional energy sources.
To address this gap, researchers at the MIT Energy Initiative, in collaboration with ExxonMobil Technology and Engineering, developed the HyCAT. The tool compares different transportation pathways and shows that the optimal hydrogen carrier depends on the specific characteristics of each supply chain.
Developing a Flexible Framework for Supply Chain Evaluation
The researchers developed the HyCAT to assess the costs and greenhouse gas emissions associated with hydrogen transportation. The tool begins its analysis after hydrogen has been produced and ends when it reaches the destination, focusing entirely on transportation, storage, and hydrogen recovery.
HyCAT evaluates five stages of the transportation process: hydrogen conversion into a transportable liquid or chemical carrier; storage at the export terminal; overseas shipping; storage at the import terminal; and the release of hydrogen for industrial use or pipeline distribution.
Users enter site-specific information such as electricity prices, shipping costs, infrastructure investments, and carbon intensity. HyCAT then estimates the overall transportation cost and greenhouse gas emissions for each pathway.
The researchers demonstrated the tool using several transportation strategies. They compared direct hydrogen liquefaction with three chemical carriers: liquid organic hydrogen carriers based on toluene, synthetic methane, and ammonia.
HyCAT is also open source, allowing researchers and industry users to update cost assumptions and technology data as the hydrogen sector continues to develop. This flexibility keeps the tool relevant as transportation technologies mature.
Choosing the Right Hydrogen Carrier for Each Supply Chain
The analysis showed that every hydrogen transportation pathway involves trade-offs between cost, energy efficiency, and carbon emissions. For example, direct hydrogen liquefaction avoids chemical conversion, but it requires extremely low temperatures. Cooling hydrogen to liquid form consumes nearly one-third of its energy content, and additional losses can occur if the liquid gradually evaporates during storage or transport.
Chemical carriers reduce some of these storage challenges but introduce new limitations. Liquid organic hydrogen carriers, such as hydrogenated toluene, store hydrogen under relatively stable conditions. However, toluene is largely produced from fossil resources, increasing the overall carbon footprint.
Synthetic methane offers another alternative by combining hydrogen with captured carbon dioxide. This approach can recycle carbon dioxide, but the reaction also produces water, resulting in hydrogen losses and lower overall efficiency.
Among the carriers evaluated, ammonia performed well in many scenarios. However, efficiently releasing hydrogen from ammonia at the destination remains a key technical challenge.
The researchers found that the best hydrogen transportation pathway depends on the supply chain. Shipping distance, energy prices, infrastructure costs, and local operating conditions all affect both cost and greenhouse gas emissions.
An option that performs well in one region may not be the best choice elsewhere. HyCAT helps users evaluate these trade-offs and identify the most suitable pathway for their specific conditions.
Enabling Smarter Hydrogen Infrastructure Planning
This study shows that large-scale hydrogen adoption depends on more than clean production technologies. Efficient transportation and storage are just as important as clean hydrogen production for delivering hydrogen to end users.
HyCAT provides policymakers, infrastructure developers, and energy companies with a practical framework for comparing transportation pathways based on both cost and greenhouse gas emissions.
Conventional studies often recommend a single transportation pathway. In contrast, HyCAT adapts its analysis to the local conditions of each supply chain. Users can update inputs as technologies improve, infrastructure expands, and market conditions change. This flexibility allows the tool to remain useful as the global hydrogen economy evolves.
The researchers plan to apply HyCAT to real-world supply chains and evaluate how uncertain economic and technical assumptions influence transportation decisions. These future studies will help identify the conditions under which specific hydrogen carriers become the preferred option.
Overall, the research shows that there is no universal solution for hydrogen transportation. Instead, successful deployment requires balancing cost, emissions, infrastructure, and regional conditions. Decision-support tools such as HyCAT can help stakeholders design more efficient hydrogen supply chains and accelerate the transition to cleaner energy systems.
Journal Reference
Ibrahim, G. et al. (2026). Hydrogen carrier analysis tool (HyCAT): Integrated economics and emissions assessment for long distance hydrogen transportation. Fuel. 428. https://www.sciencedirect.com/science/article/abs/pii/S0016236126020259?via%3Dihub.
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