LAPSE:2026.0246v1
Published Article

LAPSE:2026.0246v1
Exploring the Thermal Coupling of Solid Oxide Electrolysis and Ammonia Synthesis: A Plantwide Energy Integration Assessment
June 12, 2026
Abstract
The transition toward low-carbon ammonia production increasingly relies on highly efficient routes for renewable hydrogen generation, with Solid Oxide Electrolysis (SOE) representing a particularly promising solution. SOEs, operating with steam at elevated temperatures, offer intrinsic thermodynamic advantages and are attractive when integrated with processes that can effectively utilize or supply high-grade heat. This context opens the possibility for advanced energy coupling between hydrogen production and the exothermic ammonia synthesis process. This work investigates such an energy integration strategy by simulating a small-scale ammonia plant where hydrogen is produced through an SOE system thermally coupled to the ammonia synthesis loop. Specifically, high-grade heat available in the Haber-Bosch (HB) reactor outlet is recovered via a "Heat Recovery Steam Generator" (HRSG) to provide a substantial fraction (55 wt%) of the steam required by the electrolyzer. The assessment demonstrates that the integrated configuration significantly reduces the external electrical demand for steam generation by 84%, achieving a substantial enhancement in system-level electrical efficiency. Total plant energy efficiency increases from 57% to 62%, and the electricity-to-hydrogen ratio decreases from 45.9 to 42.1 kWh/kg. These improvements translate directly into a decrease in the Levelized Cost of Ammonia (LCOA) by 4-5%, underscoring the relevance of high-temperature electrolysis supported by effective plantwide heat recovery.
The transition toward low-carbon ammonia production increasingly relies on highly efficient routes for renewable hydrogen generation, with Solid Oxide Electrolysis (SOE) representing a particularly promising solution. SOEs, operating with steam at elevated temperatures, offer intrinsic thermodynamic advantages and are attractive when integrated with processes that can effectively utilize or supply high-grade heat. This context opens the possibility for advanced energy coupling between hydrogen production and the exothermic ammonia synthesis process. This work investigates such an energy integration strategy by simulating a small-scale ammonia plant where hydrogen is produced through an SOE system thermally coupled to the ammonia synthesis loop. Specifically, high-grade heat available in the Haber-Bosch (HB) reactor outlet is recovered via a "Heat Recovery Steam Generator" (HRSG) to provide a substantial fraction (55 wt%) of the steam required by the electrolyzer. The assessment demonstrates that the integrated configuration significantly reduces the external electrical demand for steam generation by 84%, achieving a substantial enhancement in system-level electrical efficiency. Total plant energy efficiency increases from 57% to 62%, and the electricity-to-hydrogen ratio decreases from 45.9 to 42.1 kWh/kg. These improvements translate directly into a decrease in the Levelized Cost of Ammonia (LCOA) by 4-5%, underscoring the relevance of high-temperature electrolysis supported by effective plantwide heat recovery.
Record ID
Keywords
Energy Integration, Green ammonia, Haber-Bosch process, Hydrogen, Solid Oxide Electrolysis
Subject
Suggested Citation
Macchi A, Longobardi F, Anghilante R, Isella A, Manca D. Exploring the Thermal Coupling of Solid Oxide Electrolysis and Ammonia Synthesis: A Plantwide Energy Integration Assessment. Systems and Control Transactions 5:352-359 (2026) https://doi.org/10.69997/sct.181169
Author Affiliations
Macchi A: PSE-Lab, Process Systems Engineering Laboratory, Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta", Politecnico di Milano, Piazza Leonardo da Vinci 32, 20133 Milano, Italy
Longobardi F: Casale SA, Via Giulio Pocobelli 6, 6900 Lugano, Switzerland
Anghilante R: Casale SA, Via Giulio Pocobelli 6, 6900 Lugano, Switzerland
Isella A: PSE-Lab, Process Systems Engineering Laboratory, Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta", Politecnico di Milano, Piazza Leonardo da Vinci 32, 20133 Milano, Italy [ORCID]
Manca D: PSE-Lab, Process Systems Engineering Laboratory, Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta", Politecnico di Milano, Piazza Leonardo da Vinci 32, 20133 Milano, Italy [ORCID]
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Longobardi F: Casale SA, Via Giulio Pocobelli 6, 6900 Lugano, Switzerland
Anghilante R: Casale SA, Via Giulio Pocobelli 6, 6900 Lugano, Switzerland
Isella A: PSE-Lab, Process Systems Engineering Laboratory, Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta", Politecnico di Milano, Piazza Leonardo da Vinci 32, 20133 Milano, Italy [ORCID]
Manca D: PSE-Lab, Process Systems Engineering Laboratory, Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta", Politecnico di Milano, Piazza Leonardo da Vinci 32, 20133 Milano, Italy [ORCID]
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Journal Name
Systems and Control Transactions
Volume
5
First Page
352
Last Page
359
Year
2026
Publication Date
2026-06-12
Version Comments
Original Submission
Other Meta
PII: 0352-0359-208-SCT-5-2026, Publication Type: Journal Article
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LAPSE:2026.0246v1
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https://doi.org/10.69997/sct.181169
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Jun 12, 2026
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Links to Related Works
References Cited
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