Integrated techno-economic and process simulation assessment of alkaline water electrolysis in Libya for green hydrogen production

Abstract

Background: The global energy transition requires robust green energy carriers, with green hydrogen produced by renewable-powered water electrolysis emerging as a key pathway for decarbonization. Libya, particularly the Al-Harsha site in Zawiya, offers significant potential for green hydrogen production due to its high solar irradiance (>2200 kWh/m²/year) and strategic proximity to European markets across the Mediterranean. Aim: This study aims to evaluate the technical performance and economic feasibility of alkaline water electrolysis (AWE) for large-scale green hydrogen production in Libya and to assess its potential for hydrogen export. Methods: High-fidelity steady-state simulations of AWE plants were developed using Aspen HYSYS V14.2 with the Electrolyte non-random two-liquid (NRTL) property package. Two production capacities (27.9 and 60.3 t/day) were investigated. Sensitivity analyses were performed to examine the effects of water feed flow (400–2000 kmol/h), KOH electrolyte flow (100–300 kmol/h), reactor conversion (40%–90%), and heater temperature (90°C–130°C). The process configuration included mixing units, conversion reactors arranged in series, gas–liquid separators, and electrolyte recycle streams. Results: The simulations showed that water feed flow is the primary factor governing hydrogen production, while increasing KOH electrolyte flow produced only modest improvements by reducing ohmic losses. Variations in reactor conversion and operating temperature had minimal influence on hydrogen yield, indicating that system performance is primarily constrained by mass and power availability. The techno-economic assessment estimated a levelized cost of hydrogen (LCOH) of $ 2.5–3.5/kg H₂, demonstrating the potential competitiveness of Libyan green hydrogen for export. An assessment of pipeline transport, ammonia synthesis, and liquefied hydrogen identified multiple viable export pathways for the emerging Mediterranean hydrogen corridor. Conclusion: Under the stated modeling assumptions, the proposed coastal Libyan AWE facility is technically feasible and economically competitive as a potential contributor to a future North African–European hydrogen export network. However, pilot-scale validation, dynamic renewable energy integration studies, and comprehensive logistical risk assessments are required before large-scale deployment can be recommended.