Natural gas has been used for energy production for several years. As a readily available source of energy, it is cost-effective compared to other forms like coal. When natural gas is burned, the waste products are water and carbon dioxide. The fumes released into the air contribute to climate change, causing harm to the environment.
Green hydrogen could help produce energy without polluting, avoiding the use of fossil fuels. Compared to natural gas, the only byproduct deriving from green hydrogen combustion is water. The element is also lightweight, which means it can be used for transportation by road, air, and shipping. However, hydrogen has to be produced on a large scale to be an alternative to natural gas.
Considering the infrastructure and equipment needed, this is still a challenge for most companies. Nevertheless, scientists are developing new techniques for optimisation and sustainability. Let’s explore this article to learn about the latest innovations designed to enhance the process of producing hydrogen.
Key Challenges in Hydrogen Production
As earlier indicated, producing large volumes of hydrogen is still tricky. Power plants must first find solutions to the many challenges before hydrogen becomes a dependable source of electricity.
The first and most significant one is about the energy required to produce green hydrogen. Most companies in the energy sector use water electrolysis, a promising technology, but characterised by high energy consumption. If the electricity used comes from fossil fuels, the environmental impact remains significant. Only the use of renewable sources, such as solar and wind, can make hydrogen a truly sustainable resource — even though today they still don’t ensure consistent supply.
The second major challenge is the infrastructure needed to produce, store and transport it. Unlike other energy sources like oil and natural gas, no hydrogen-specific pipelines, refuelling stations, or storage facilities exist. Additionally, the current production technique focuses on small amounts. Reliable systems must be built first for hydrogen to impact the global stage.
The production of green hydrogen is also still expensive. Costly equipment like electrolysers are required in the production process, which is resource-intensive compared to traditional fuels. Many countries are waiting for an efficient process or for prices to drop. Solving these challenges is the key to making hydrogen a solution for clean energy.
Advanced Technologies for Hydrogen Production Optimisation
Although hydrogen production is still challenging, new technologies make the process more efficient.These tools and systems are designed to address the issues related to hydrogen production.
Next-Generation Electrolysis Systems
Electrolysis is the process of using electricity to split water into hydrogen and oxygen gas. This technique has been used for the past few years. However, new electrolysers are on the market to improve the machines. These are:
- AEL (Alkaline Electrolysis) uses an alkaline electrolyte, typically sodium hydroxide (NaOH) or potassium hydroxide (KOH), to conduct ions. The solution passes through a diaphragm separator, and an electric current splits water into hydrogen and oxygen.
- PEM Electrolysers (Proton Exchange Membrane) – These devices work well with renewable energy like wind and solar. They can easily be started and stopped, making them suitable for handling power input fluctuations
- SOEC (Solid Oxide Electrolysers) for Industrial-Scale Applications – This type of machine can be used in large factories and plants. It operates at high temperatures, but the heat can be used in other processes. This will save electricity, especially for industries with high hydrogen demand.
In this context, companies specializing in electrical energy conversion, such as FRIEM, are contributing to the development of advanced solutions to power electrolysers efficiently and at scale. Thanks to modular and high-precision systems, it is possible to improve process performance and facilitate integration into industrial plants of various sizes.
High-Efficiency Power Converters for Electrolysis
Before power is used in electrolysis, it must be converted from AC (Alternating Current) to DC (Direct Current). This means efficient converters are required to run the process.
Multilevel converters – devices that uses several voltage levels to produce a smoother output waveform, reducing harmonics and improving efficiency compared to traditional two-level converters – also improve the efficiency of the machines by reducing energy lost during conversion. These tools are vital for hydrogen plants to use electricity wisely, mainly when they focus on renewable sources.
Renewable Energy Integration for Cost-Effective Hydrogen
As indicated earlier, renewable energy is among the most environmentally friendly hydrogen production methods. However, this still comes with various challenges that affect its cost-effectiveness. The first solution is innovative energy systems – devices can regulate the amount of power produced depending on renewables availability.
Since solar and wind production is inherently variable, plants require effective hydrogen storage systems. This allows excess energy to be converted and stored as hydrogen for later use.
Thanks to high-precision energy conversion solutions, FRIEM enables companies to manage the power supply to electrolysers in a stable and flexible way, even in the presence of fluctuations in the electrical grid. This support is essential to ensure operational continuity and maximize process efficiency.
Scale-Up Strategies for Hydrogen Production
To become a key part of the global clean energy mix, green hydrogen needs to be produced at scale. While the transition will take time, adopting innovative strategies can help accelerate its rollout.
Expanding Electrolysers capacity
Electrolysers are integral in the production of hydrogen. Most of these machines aren’t big, since they are used in small projects. The first strategy is to use modular electrolysers or small building blocks that combine to increase production. This flexibility will help companies start small and grow over time. They can adapt to the changing needs of customers.
Another option is to build gigafactories or large manufacturing plants. Such facilities would be responsible for mass-producing electrolysers, and this would also reduce the cost of production and help meet the growing demand.
Enhancing Hydrogen Infrastructure
As one of the main problems in hydrogen production is the lack of infrastructure, the next step is to develop networks and facilities capable of supporting its production, transportation, and use. Pipelines are essential for transporting hydrogen over long distances: many of the systems currently used for natural gas can be adapted or converted for this purpose.
Refuelling stations are also needed for hydrogen-powered cars. Although some vehicles will use a small amount of it, trucks and buses may require large quantities. This calls for well-equipped stations to gas up every kind of vehicle.
Hydrogen is expected to play a key role in various industries, such as steel and ammonia production, where it may replace fossil fuels as an energy source to reduce carbon emissions.
Policy and Financial Incentives for Large-Scale Hydrogen Adoption
Governments and organizations are crucial to scale-up hydrogen as a reliable energy source. Many countries have grant tax, tax credits, and subsidies to promote the development of plants and the adoption of hydrogen-related technologies. For producers, those measures make equipment more affordable and and easier to access, which in turn helps support hydrogen projects and its use as an energy source.
Private companies can contribute to this growth through direct investments, strategic partnerships, or support for organizations dedicated to clean energy production. An additional boost can come from outreach; promoting awareness of hydrogen among the general public and encouraging its use in industrial processes is essential for a shared energy transition.
In this context, FRIEM colleborates with numerous partners worldwide to provide reliable, high-efficiency systems for large-scale hydrogen production plants.
Sustainability and Efficiency in Hydrogen Production
With the integration of hydrogen into the future energy landscape, it becomes essential to ensure its production is sustainable and efficient. This means optimizing resource use, reducing waste, protecting the environment, and keeping production costs under control. Here are a few ways to achieve so.
Reducing Water Consumption in Electrolysis
Hydrogen is obtained by splitting H2O through electrolysis. However, clean water is limited in most places. For this reason, many studies are exploring the use of seawater or brackish water as an alternative to freshwater.
Some next-generation systems are designed to use treated wastewater, which is already available in various urban contexts. An important role in this evolution is played by the development of new ion-exchange membranes, components that allow hydrogen and oxygen to be separated during electrolysis. The latest versions are designed to operate even with non-potable water, reducing freshwater demand while improving both efficiency and process purity.
Circular Economy Approaches in Hydrogen Production
A circular economy means reusing energy and resources to minimize waste. In most factories, a significant part of the heat produced is released into the air. The new heat recovery systems, on the other hand, make it possible to reuse this heat to power hydrogen production, improving overall efficiency and reducing energy consumption. From a circular perspective, other industrial processes can also contribute to clean energy production by exploiting by-products such as organic waste, which can be converted into biogas, or residual gases from industrial operations.
Another circular approach in blue hydrogen production is using natural gas instead of water. Its carbon capture technology traps CO2 (CCS). In this way, the carbon can be retained before being released into the atmosphere and can be stored or used in other production industries, helping to reduce the environmental impact and make the entire hydrogen value chain more sustainable.
The Future of Green Hydrogen as a Global Energy Carrier
Green hydrogen represents one of the most promising solutions for a sustainable energy future. Its production relies on clean energy sources like hydropower, solar and wind to reduce significantly environmental impacts compared to fossil fuels. One of hydrogen’s exciting uses is in fuel cells, which can power cars, trucks, buses, trains, and even ships, Contributing to the decarbonization of the transport sector.
It can also act as a storage solution for energy, which is particularly useful since solar and wind power are not always available. In such cases, surplus electricity from these sources can be stored and used later when needed.
Looking ahead, companies and research centers are still working on the best way to transport hydrogen globally. Possible solutions include a liquid form or the conversion of more stable compounds, such as ammonia or liquid organic carriers, to facilitate their transportation on a global scale. Thanks to these advances, green hydrogen could establish itself as the energy carrier of the future, capable of supporting a transition toward a clean, efficient, and sustainable energy system.