Techno-economic comparison of ammonia cracking and separation using metal membrane and pressure swing adsorption

Ammonia is a promising hydrogen (H2) carrier, enabling efficient storage and transport. This study presents a comparative techno-economic assessment of two hydrogen separation approaches downstream of ammonia cracking: pressure swing adsorption (PSA), which is commercially established, and metal membrane separation, which remains at an early stage of development. Based on literature data, metal membranes achieve 99 % hydrogen purity, while PSA yields 85 % recovery. Techno economic analysis shows metal membranes consume 7.4 MWh per tonne H2, compared to 8.5 MWh per tonne H2 for PSA. Metal membranes also involve higher material costs and embrittlement risks, while PSA offers lower capital and operating costs. Economic analysis shows metal membranes yield a net present value (NPV) of USD 420 million and internal rate of return (IRR) of 28 %, while PSA achieves USD 410 million (NPV) and 25 % IRR. PSA remains more viable for large scale use, while membranes may suit high purity applications.