Fuel cell vehicles (FCVs) powered with hydrogen (H2) have the potential to achieve great energy and environmental benefits relative to petroleum-powered internal combustion engine (ICE) vehicles. As an energy carrier, H2 offers an opportunity to diversify sources of transportation energy supply. H2-powered FCVs offer zero emissions during vehicle operation. To realize these potential benefits, tremendous research and development (R&D) efforts are being undertaken by governments and industries worldwide to advance FCV technologies and lower costs of H2 production, transportation, and storage.

At present, H2 is produced mostly from natural gas (NG) via steam methane reforming (SMR). For FCV applications, both near- and long-term H2 production options are being explored. One of the H2 production options that has not been examined is the potential H2 production from coke oven gas (COG) from the coking process in steel mills. The U.S. steel industry produces about 300 billion cubic feet of COG a year. With the H2 content of more than 50% by volume in COG, separation of H2 from COG could result in 370,000 metric tons of H2 produced a year in the U.S.

In this paper, we examine energy and emission effects of this production option on the well-to-wheels basis in comparison with other H2 production options as well as with conventional gasoline and diesel options. We then estimate the magnitude of H2 production from COG in the U.S. and the number of H2 FCVs that can be fueled with the amount of H2 produced.