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Factsheet Hydrogen Safety

Hydrogen is set to become one of the pillars of the energy transition. Particularly in the industry sector, as well as in the electricity, heating and mobility sectors, it can play a crucial role in reducing CO₂ emissions as both an energy carrier and a feedstock. This entails the developments of electrolysis plants for hydrogen production, infrastructure for transport, import and storage, as well as new facilities for hydrogen applications. As in every area of the energy sector, all components of these facilities are subject to regulatory approval. In Germany, this ensures that all risks are managed through technical measures, protective equipment and state of the art processes, regulatory requirements are met, regular inspections are conducted, and emergency and safety concepts are in place.

1. What are the characteristics of hydrogen with regard to safety?

Hydrogen is 14 times lighter than air. When hydrogen is released, it immediately rises upwards and disperses very quickly – unlike petrol or propane, for example, which settle at ground level. This is an important safety advantage.
Pure hydrogen, e. g. in tanks or pipelines, is not combustible. Only when hydrogen is mixed with air (at concentrations of 4-77 %) does a flammable mixture form. In ambient air, hydrogen is highly flammable and burns with an almost invisible flame that radiates little heat.
As with natural gas, the safe handling of hydrogen requires specific safety measures, including explosion-protected equipment, gas detection systems, and appropriately trained personnel. In particular, operational experience from the natural gas sector can be readily applied to hydrogen infrastructure.
The chemical industry in Germany has been using hydrogen in large quantities for more than 100 years.

2. How is the safe transport of hydrogen ensured?

Hydrogen will be transported in large volumes through underground pipeline networks. As with natural gas, there will be national transmission networks and, in some cases, local distribution networks within cities.
The transport of hydrogen by pipelines is governed by the regulations of the German Technical and Scientific Association for Gas and Water (DVGW). All components used in the pipelines and stations are approved and tested specifically for hydrogen transport.
Specialist personnel are specifically trained, including at an H₂ training line that GET H2 partner OGE has set up in Werne.
The pipelines and stations are subject to regular inspections and maintenance. As with natural gas networks, aerial surveys are conducted, and advanced inspection devices (known as pigs) are used to examine the pipelines internally. Some sensor systems have been specially developed for the hydrogen network.
Companies such as GET H2 partners SYNEQT, BASF, Air Liquide, Linde and Salzgitter already operate safe local and regional hydrogen networks spanning several hundred kilometers.

3. How is hydrogen safely produced?

For the storage of hydrogen, underground salt caverns (cavern storage) and former natural gas deposits (pore storage) are primarily planned. These storage facilities are the most important storage sites for natural gas as well. Pilot projects have shown that they are also suitable for hydrogen storage.
As with natural gas, the storage facilities and the necessary infrastructure have extensive safety systems such as pressure relief systems, leak detectors and emergency shutdowns.
Smaller quantities of hydrogen are often transported and stored either as compressed gas in high pressure containers or in liquid form at cryogenic temperatures. This method of storage has been tried and tested in the industrial gases sector for decades. The containers are subjected to pressure, fire, and ballistic tests before approval, and are regularly inspected by TÜV or BAM.

4. How is hydrogen safely stored?

Two processes are prominent in hydrogen production:

For almost 100 years, hydrogen has been produced in the chemical and petrochemical industry through steam reforming, a process in which natural gas is split into its components.
For the development of the hydrogen economy, electrolysis plays the primary role. In this process, water is split into hydrogen and oxygen using electricity. Chlor-alkalielectrolysis has been carried out on an industrial scale for more than 100 years. PEM electrolysis and solid oxide electrolysis were developed in the 1960s.

Both production methods are subject to strict regulations and stringent safety requirements. For the production of green hydrogen, adaptable electrolysers are essential. The operation of these plants is adapted accordingly, with all necessary safety measures implemented. When approving industrial-scale facilities, safety, location and environmental impacts are closely examined.

5. How is hydrogen used safely in industry the industry sector?

Hydrogen is used in the industry sector in three different ways:

As a feedstock in the chemical industry for the production of basic chemicals, intermediates and precursors for sectors such as the pharmaceutical industry, the plastics industry, and agriculture.
As a process gas, e. g. in refineries for the desulphurisation of fuels, in steel production for iron ore reduction, as well as for heat treatment of steel or for cleaning in the semiconductor industry.
As an energy source for generating high-temperature process heat. In furnaces used in the steel, glass, or brick industries, hydrogen can replace fossil fuels.

Established applications are governed by robust safety concepts, including gas-tight installations, gas detection systems, inerting, and emergency response plans. These facilities are subject to the Industrial Safety Ordinance (Betriebssicherheitsverordnung) and, for larger quantities, the Major Accidents Ordinance (Störfall-Verordnung). For new applications such as hydrogen-based direct reduction plants for the production of green steel, companies such as GET H2 partner Salzgitter have installed extensive protective equipment and sensors.

6. How is hydrogen used safely in other sectors such as mobility, electricity generation, and heating?

Hydrogen also has potential applications in sectors such as transport, electricity generation, and heating in buildings. Here too, measures are taken to ensure safe application from the outset.

Mobility

Fuel cell vehicles are subject to the same safety standards as conventional cars. Their tanks are crash-tested and remain intact even in severe accidents. In the event of a collission, the system immediately shuts off the hydrogen supply. Filling stations are subject to the Industrial Safety Ordinance and require a permit to dispense hydrogen.

Electricity generation

New gas-fired power stations being constructed in Germany are to allow conversion to hydrogen. This is achieved through turbines designed for hydrogen combustion. The other technologies and safety concepts correspond to those for natural gas, but take into account the specific properties of hydrogen. As with all power stations, these facilities would also be regularly inspected by TÜV or other testing bodies.

Heating

The use of hydrogen in homes is currently being tested in pilot projects – both as blend with natural gas and in dedicated hydrogen appliances. These gas appliances must be certified for hydrogen use. Installers and chimney sweeps receive appropriate training.

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