Hydrogen Manufacturing: Creating the Bright Future of Green Energy 

Main Takeaways: 

• Hydrogen manufacturing is crucial to sustainable energy production, offering a cleaner, more versatile alternative to fossil fuels.
• Electrolysers play a key role in splitting water into hydrogen and oxygen using electricity.
• The three main types of electrolysers are alkaline, PEM (Proton Exchange Membrane), and SOEC (Solid Oxide Electrolyser Cells), with alkaline being the most established and widely used.
• Green hydrogen is produced using renewable energy, and it is essential for decarbonising sectors such as heavy transportation, heavy industries, and energy storage.
• The future of hydrogen manufacturing involves improving efficiency, reducing costs, and expanding infrastructure to meet the growing global demand.

The Basics of Hydrogen Manufacturing 

Hydrogen manufacturing has emerged as one of the most promising solutions to the world’s growing energy needs, particularly as we shift away from fossil fuels. At its core, hydrogen is the simplest and most abundant element in the universe, but it is rare in its pure form on Earth—therefore it must be produced. Hydrogen manufacturing can be done in several ways, but here we will focus on the methods that are environmentally sustainable and aligned with global decarbonisation goals. 

Why is Hydrogen Manufacturing Important? 

The importance of hydrogen manufacturing lies in the fact that hydrogen is a versatile energy carrier. When produced cleanly, hydrogen can be used to store, transport, and deliver energy across various applications. Unlike fossil fuels, hydrogen doesn’t release carbon dioxide (CO₂) when burned or used in a fuel cell. Instead, the only by-product is water, making it a clean alternative for power generation, transport, and industrial processes. 

Different Types of Hydrogen 

Before diving into how hydrogen is produced, it’s important to understand some of the different types of hydrogen based on how it’s made: 

• Grey hydrogen: Produced from natural gas using a process called steam methane reforming (SMR), which releases CO₂ as a by-product. While this method is currently the most common, it has a high carbon footprint.
• Blue hydrogen: Also produced from natural gas, but with the addition of carbon capture and storage (CCS) technology. The CO₂ emissions are captured and stored underground, making it a lower-carbon option than grey hydrogen.
• Green hydrogen: Produced through water electrolysis using renewable electricity (such as wind, solar, or hydropower). This is the cleanest form of hydrogen manufacturing as it generates zero CO₂ emissions.

For the purposes of this article, our focus will be on green hydrogen, as it aligns with the growing global push towards renewable energy and a sustainable future. If you want to know more, read our article about the colors of hydrogen.

How Electrolysers Work 

At the heart of green hydrogen manufacturing is the electrolyser. Electrolysers are devices that use electrical energy to drive a chemical reaction, in this case, splitting water (H₂O) into its two components: hydrogen (H₂) and oxygen (O₂). The process is known as water electrolysis. 

The concept is simple enough: an electrolyser takes in water, applies electricity to it, and produces hydrogen and oxygen. However, the technology behind this process is highly sophisticated and crucial to the entire hydrogen economy. 

Key Components of an Electrolyser 

An electrolyser is made up of several key parts, here are the 3 main parts: 

• Electrodes: These are where the electrochemical reactions take place. One electrode (the anode) pulls electrons from the water molecules and facilitates oxygen evolution, while the other electrode (the cathode) facilitates the formation of hydrogen molecules.
• Electrolyte: This medium allows ions to move between the two electrodes. The type of electrolyte used differs between the various electrolyser technologies.
• Power supply: To drive the reaction, a source of electricity is required. The cleaner the electricity source, the cleaner the resulting hydrogen. When using renewables like wind or solar, the hydrogen produced is considered green.

The Electrolysis Process 

The overall electrolysis process involves passing an electric current through water to split it into hydrogen and oxygen. The reaction can be summarised by the following equation: 

2H2O(l)→2H2(g)+O2(g)2H₂O (l)

The hydrogen gas is then collected, purified, and stored for future use, while the oxygen is typically vented to the atmosphere, though in some cases, it can be captured for industrial use. 

Electrolysers can be scaled up or down depending on the specific application, from small-scale systems for individual buildings to large industrial-scale units for hydrogen manufacturing at a national level. The scalability of electrolysers is one reason they’re being heavily invested in as part of the green hydrogen revolution. 

Read our article about electrolysers, they are the backbone of Green Hydrogen Production.

The Three Main Types of Electrolysers 

Currently, there are three main types of electrolysers that are used to produce hydrogen, each with its own advantages and disadvantages. Let’s explore them briefly and discuss why alkaline electrolysers are the most established and widely used. 

1. Alkaline Electrolysers 

Alkaline electrolysers are the oldest and most commercially established technology. They operate using a liquid electrolyte, typically potassium hydroxide (KOH), to conduct ions between the anode and cathode. 

Advantages of alkaline electrolysers: 

• Maturity: Having been used for over a century, alkaline electrolysers are a proven technology with a long operational track record.
• Cost-effectiveness: Compared to other types, alkaline electrolysers are relatively inexpensive to manufacture and maintain, making them the preferred choice for large-scale hydrogen production.
• Durability: Alkaline systems are highly durable and able to operate for extended periods under stable conditions.

Drawbacks: 

• Response time: They are slower to respond to changes in electricity supply, making them less compatible with the fluctuating nature of renewable energy sources like wind and solar.
• Efficiency: While being much more reliable, alkaline electrolysers sometimes have lower overall efficiency than newer technologies like PEM and SOEC.

At Stargate Hydrogen, our focus is on maximising the potential of alkaline electrolysers for industrial applications, particularly where high volumes of hydrogen are required, such as in steelmaking and chemical industries. 

2. PEM (Proton Exchange Membrane) Electrolysers 

PEM electrolysers use a solid polymer membrane to conduct protons from the anode to the cathode. These systems have a faster response time compared to alkaline systems, making them ideal for pairing with intermittent renewable energy sources. 

Advantages of PEM electrolysers: 

• Flexibility: They can handle fluctuating power inputs, making them well-suited for use with solar and wind energy.
• Compact design: PEM systems tend to be more compact than alkaline electrolysers, which is useful for space-constrained applications.

Drawbacks: 

• Cost: PEM electrolysers are more expensive to produce, due to the need for expensive materials like platinum and iridium for the catalyst. 

3. SOEC (Solid Oxide Electrolysers) 

SOECs are the newest and least commercially developed type of electrolyser for hydrogen manufacturing. They operate at very high temperatures (typically between 500°C and 1,000°C), which improves their efficiency by allowing them to utilise both heat and electricity to split water. 

Advantages of SOECs: 

• High efficiency: SOECs are more efficient than alkaline and PEM electrolysers because they utilise both thermal and electrical energy. 
• Heat integration: SOECs can be integrated with industrial processes that produce excess heat, making them more energy-efficient. 

Drawbacks: 

• Complexity: SOECs are more complex and currently less mature, with most applications still in the research and development phase. 
• Durability: The high operating temperatures can lead to faster wear and tear, making durability an ongoing challenge. 

To learn more about different types of hydrogen manufacturing, read our explaining the basics of water electrolysis

Overview of Green Hydrogen 

Green hydrogen, produced by electrolysis powered by renewable energy, is at the forefront of global efforts to decarbonise industries, transport, and energy systems. Unlike grey and blue hydrogen, green hydrogen is entirely carbon-free, making it a critical tool in reducing global greenhouse gas emissions. 

Why is green hydrogen manufacturing so important? 

In a world where industries and governments are increasingly prioritising sustainability, green hydrogen offers a way to cut carbon emissions from sectors that are traditionally difficult to decarbonise. For example: 

• Heavy industry: Sectors like steel, cement, and chemicals produce vast amounts of CO₂. Green hydrogen can replace fossil fuels in these energy-intensive processes, significantly lowering emissions.
• Heavy Transport: Hydrogen fuel cells are being explored for use in heavy-duty vehicles, including trucks, buses, and trains. Unlike battery electric vehicles, which require long charging times, hydrogen fuel cells can be refuelled in minutes, making them ideal for long-range transport applications. 
• Energy storage: Renewable energy sources like wind and solar are intermittent—they don’t always generate electricity when it’s needed. Green hydrogen can serve as a storage medium, capturing excess electricity and converting it into hydrogen for later use in power generation or other applications.  

In short, green hydrogen manufacturing has the potential to decarbonise a wide range of sectors, helping countries around the world meet their climate goals. 

Applications of Green Hydrogen 

The versatility of hydrogen means it can be used across a wide array of industries and applications. Here’s a deeper look at some of the key uses for green hydrogen: 

1. Transport 

Hydrogen fuel cell vehicles (FCVs) are seen as a key part of the future of clean transport. While battery electric vehicles (BEVs) are ideal for light-duty vehicles and short distances, FCVs have the advantage in heavy-duty transport and long distances. Hydrogen’s high energy density means fuel cell vehicles can travel further without the need for frequent recharging. Refuelling takes minutes, which makes it ideal for industries like trucking, public transport, and even aviation. 

Countries like Japan and South Korea are leading the charge in rolling out hydrogen refuelling stations, while Europe is heavily investing in hydrogen-powered buses and trucks. The aviation industry is also experimenting with hydrogen-powered aircraft, which could significantly cut the sector’s carbon emissions. 

2. Industrial Processes 

Heavy industry is one of the most difficult sectors to decarbonise, but green hydrogen offers a way to do it. Industries such as steel, chemicals, and cement require high amounts of energy, and many processes emit large quantities of CO₂. Green hydrogen can replace coal and natural gas in these processes, providing the high heat needed for industrial reactions without the emissions. 

For example, in steelmaking, green hydrogen can be used as a reducing agent, drastically reducing the amount of CO₂ emitted during production. This is one of the most exciting applications of green hydrogen and has the potential to transform the global steel industry. 

3. Energy Storage 

One of the challenges of renewable energy is its intermittency. Solar panels only generate power when the sun is shining, and wind turbines only spin when the wind is blowing. This creates a mismatch between supply and demand, particularly during peak usage times. Green hydrogen can help solve this problem by storing excess renewable electricity as hydrogen, which can later be converted back into electricity when needed. 

This approach can also provide backup power for grid systems, ensuring a stable supply of electricity even when renewable sources are unavailable. 

4. Heating 

Green hydrogen can be used as a clean alternative to natural gas for heating in both residential and industrial settings. Hydrogen can be blended into existing natural gas pipelines or used in dedicated hydrogen networks to provide heat for homes, factories, and power plants. While this application is still in its early stages, it offers another promising avenue for reducing the carbon footprint of heating systems. 

Learn more about green hydrogen being a proven Sustainable Energy Game-Changer.

The Future of Hydrogen Manufacturing 

The future of hydrogen manufacturing is full of promise but also faces significant challenges. In the coming years, the focus will be on improving the efficiency of electrolysers, scaling up production to meet global demand, and reducing the costs associated with green hydrogen. 

Key Trends to Watch 

1. Cost Reduction: One of the main obstacles to widespread green hydrogen adoption is cost. Currently, green hydrogen manufacturing is more expensive than grey or blue hydrogen. However, as electrolyser technologies improve and the cost of renewable energy continues to fall, the price of green hydrogen is expected to decrease significantly over the next decade. 

2. Infrastructure Development: Scaling up hydrogen production will require significant investment in infrastructure. This includes building more electrolysis plants, establishing hydrogen storage facilities, and expanding hydrogen refuelling networks for vehicles. Governments around the world are already investing in these initiatives, with Europe leading the way in hydrogen infrastructure development. 

3. Policy Support: Government policies and incentives will play a crucial role in driving the growth of green hydrogen. Carbon pricing, subsidies for renewable energy, and regulations that encourage the adoption of hydrogen technologies will all be important factors in making green hydrogen economically viable on a large scale. 

4. Technological Innovation: Advances in electrolyser technology will be critical to making hydrogen manufacturing more efficient and affordable. Research is currently underway to develop next-generation electrolysers that can operate at higher efficiencies, lower temperatures, and lower costs. Innovations like ceramic nanoparticles, developed by projects such as the EXSOthyc initiative, could help accelerate the transition to more efficient and scalable hydrogen production systems. 

The Role of Stargate Hydrogen 

At Stargate Hydrogen, we’re at the forefront of these technological advancements. Our team is dedicated to pushing the boundaries of electrolyser performance, developing solutions that are both cost-effective and scalable for industrial applications. We believe that hydrogen will play a central role in the future energy landscape, and we’re committed to helping our clients navigate this transition with the best possible solutions. 

Conclusion 

Hydrogen manufacturing is a cornerstone of the clean energy future. From reducing carbon emissions in heavy industry to providing clean fuel for transportation and energy storage, green hydrogen holds immense potential. As we continue to innovate and improve the efficiency of electrolysers, the promise of a hydrogen-based economy is becoming more achievable. 

If you’re interested in exploring how green hydrogen can transform your business or would like to learn more about our cutting-edge electrolyser technology, reach out to the experts at Stargate Hydrogen. We’re here to help you make the transition to a cleaner, more sustainable energy system. 

Ready to see how hydrogen can power your future? Get in touch with the team at Stargate Hydrogen to learn more about our innovative solutions in hydrogen manufacturing.