Techno-Economic Assessment of PEM Electrolysis for O2 Supply in Activated Sludge Systems—A Simulation Study Based on the BSM2 Wastewater Treatment Plant

The conversion of renewable energy into hydrogen (H2) by power-to-gas technologies involving electrolysis is seen today as a key element in the transition to a sustainable energy sector. Wastewater treatment plants (WWTP) could be integrated into future green H2 networks as users of oxygen (O2) produced alongside H2 in water electrolysis. In WWTPs, O2 is required for biological treatment steps, e.g., in activated sludge (AS) systems. However, the production costs of electrolysis O2 should be competitive with those of conventional O2 production processes. In this study, mathematical models of a polymer electrolyte membrane electrolyser (PEME) plant and the WWTP of the Benchmark Simulation Model No. 2 (BSM2) were used to simulate electrolysis O2 supply to an AS system and estimate net costs of production (NCP) for produced O2 via a techno-economic assessment (TEA). Assuming that produced H2 is sold to a nearby industry, NCPs for O2 were calculated for two different PEME plant dimensions, four alternatives regarding electricity supply and costs, and three sets of assumptions regarding system performance and market conditions. The analyses were performed for 2020 as a reference year and 2030 based on forecasts of relevant data. Results of the dimensioning of the PEME show the O2 demand of a municipal WWTP with an installed capacity of 80,000 population equivalents (PE), such as the one of the BSM2, can be covered for more than 99% of the simulated period by either a 6.4 MW PEME operated for 4073 full load hours or a 4.8 MW PEME operated for 6259 full load hours. Investment costs for the PEME stacks and the operational costs for electricity make up most of the NCP of electrolysis O2. The projected decrease in PEME stack costs and renewable energy prices in favourable market conditions can result in a competitive NCP for electrolysis O2 in 2030. The approach described in this study can be applied to analyse O2 supply to biological wastewater treatment in WWTPs with different characteristics, in processes different from AS, and under different assumptions regarding economic conditions.