Hydrogen Production

What are the Biggest Challenges Facing Hydrogen Production?

Due to the nature of current renewable energy production as well as the nature of the gas itself, many challenges face the production of hydrogen in order to make it safe and efficient for mass scale development and distribution.

Until now, hydrogen has been produced mainly via steam reformation and used within industrial applications – a process that creates an abundance of damaging CO2 emissions and therefore decreasing importance. In the future, the demand for hydrogen will grow due to additional consumers from sectors such as mobility seeking its benefits. However, in order for this to remain sustainable and to reach climate goals in all application areas, the CO2 footprint of hydrogen needs to be reduced.

Electrolysis as the key element to produce green hydrogen from renewable energy

As the demand for green hydrogen rises, the core technology used for hydrogen production – electrolyzer technology – will gain huge momentum and transition from the current small-scale technical demonstrator projects to large-scale industrial facilities in the multi-megawatt range. While encouraging, this development is accompanied by huge challenges for all involved parties as several new requirements need to be fulfilled:

• Economical: to be competitive, produced hydrogen needs to be cheap and necessary investments have to be secure.
• Technological: the requirements to achieve an efficiency level are high along with the lifetime, operation reliability and flexibility of the operation.

What Technologies are Being Used to Produce Hydrogen?

An electrolyser is the hydrogen core technology, as it converts electric energy into hydrogen with water. If the electric energy comes from renewable sources, such as solar or wind power, the hydrogen produced will be carbon-free. 

There are three relevant water electrolysis methods today: 

• AEL: alkaline electrolysis using a liquid-based electrolyte.
• PEMEL: acid-based electrolysis with a proton exchange membrane and a solid polymer electrolyte.
• SOEL: high-temperature electrolysis with solid oxide as the electrolyte.

Based on the Technology Readiness Level of the corresponding technology, some methods are already being implemented on a megawatt-scale. 

The AEL & PEM electrolysis methods are the most installed technologies, with the latter gaining momentum in the market in the recent years. Due to its fast response time, PEM electrolysis can be used for grid balancing. While SOEL electrolysis has the lowest maturity index, the potential in the future is bright due to not only the use of electricity but also heat to produce hydrogen.

Hydrolysis plants are typically not being built as a stand-alone electrolyser solution. Depending on the end use of the produced hydrogen, a combination of other downstream processes is being used. For example, a combination with modules such as H2 Purification, H2/O2 Liquification or Methanization.

Why Choose TÜV SÜD’s services for Hydrogen Production?

Over the past 30 years, TÜV SÜD has been a global partner across the hydrogen industry on numerous projects. As a result, not only are we well-equipped to provide support for projects such as those for Power2Gas facilities in Europe but are able to also do so on a global scale, from ideation to operation over the whole life cycle.

At TÜV SÜD, we are committed to building on our extensive experience during the planning, construction and commissioning phase of industrial process plants, energy plants and facilities and applying our vast expertise in projects covering hydrogen production. 

TÜV SÜD offers a comprehensive service portfolio for investors, manufacturers and operators of such facilities.

Hydrogen Services for Investors

Green energy is being encouraged more and more by several governments, therefore making investing in projects in which green hydrogen is produced on a large scale an attractive opportunity. Despite this, the newness and uncertainty of these projects means renewable energy investments face a lot of risks and challenges. 

TÜV SÜD is able to support the investment decision by offering project risk assessments and project due diligence. Through this, you should gain a fuller understanding of the risks and growth involved in your potential investment and therefore have more confidence in your decision making.  

Hydrogen Services for Manufacturers and EPCs

TÜV SÜD ensures the safety and security of Power2Gas-facilities by offering:

• Notified Body services: certification of assemblies and components according to international standards, e.g. pressure equipment directive.
• Assessment of safety concepts of components, assemblies and whole systems.
• Assessment of risk analysis (e.g. FMEA, HAZOP, RMAS) and HAZOP moderation.
• Component testing in accredited labs:
  • Material analysis
  • Pressure and tightness
  • Lifetime and durability assessments
  • Ballistic and fire test.
• Requirements regarding CE conformity declaration.
• Requirements regarding regulations, codes & standards (RCS) for market access in international markets.
• Staff training for safe treatment of gaseous media like hydrogen.

Hydrogen Services for Operators

Operators of hydrogen facilities can benefit from our huge experience as we offer:

• Commissioning assessment.
• Regular inspections accredited to National Law.
• Assessment of safety concepts of the whole system.
• Assessment of risk analysis (e.g. FMEA, HAZOP, RMAS) and HAZOP moderation.
• Support for preparation of safety-relevant documents, such as explosion protection document, hazard analysis.
• Support during approval procedures with authorities.
• Performance testing of whole system.
• Staff training for safe treatment of gaseous media like hydrogen as required accredited to the industrial safety regulation (BetrSichV).
• Certification of hydrogen origin accredited to international and own standards.

Alongside these services, we also offer a range of more detailed, case-by-case services that we can support you with. To find out more about what we offer or to partner with us for our hydrogen production services, get in touch.