Hydrogen is presented as a renewable and clean fuel source given it does not produce harmful emissions at its point of use. However, presently most hydrogen production comes from fossil gas. Termed ‘grey hydrogen’ the fuel is generated from natural gas, or methane, through a process called “steam reforming”[i]. The process is slightly less harmful than black or brown hydrogen production which uses black (bituminous) or brown (lignite) coal in the hydrogen-making process. The IEA (International Energy Agency) estimates that production of grey hydrogen generates 10-12 Kg of carbon dioxide equivalent (CO2e) emissions for every Kg of hydrogen produced[ii].
An alternative to this process is so-called ‘blue hydrogen’, which uses carbon capture to reduce emissions produced from using fossil gas, however this method reportedly fails to capture between 5% and 15% of the CO2 produced. Instead, the most promising (and environmentally sympathetic) extraction method is ‘green hydrogen’, which is produced by splitting water using electricity from renewables, therefore with minimal emissions.
Unfortunately, green hydrogen production remains in its infancy due to both its cost and current technological constraints. The most recent data from the IEA finds that hydrogen production reached 97 Mt (Metric tonnes) in 2023, of which less than 1% was classed as low emissions. The 2024 Global Hydrogen Review reports that based on announced projects, low-emissions hydrogen could reach 49 Mtpa (Metric tonnes per annum) by 2030.
To help advance the development of the green hydrogen market new technologies and processes are required to cut costs and improve efficiency. In the following sections we discuss three recent innovations which could help support greater adoption of green hydrogen as a fuel source.
US clean energy provider SunHydrogen recently revealed that its 1.92m2 commercial hydrogen module had successfully passed live testing. Conducted in an open prototype housing, the company states that the demonstration marks a pivotal milestone in the company’s path toward commercial-scale, renewable hydrogen production.
SunHydrogen’s Panel technology uses sunlight and any source of water to produce low-cost renewable hydrogen. Tim Young, CEO of SunHydrogen has said: “This successful demonstration of the commercial-size reactor underscores the progress we’ve made in bringing our technology out of the lab and into the real world,”[iii]
The next step for the organisation is a test of the hydrogen module inside a closed, specially designed proprietary housing unit for continuous operation. In this configuration, hydrogen and oxygen will be extracted continuously while the water is recirculated. SunHydrogen says that demonstrating continuous, closed‑system operation will form the cornerstone of a further pilot in which it plans to deploy sixteen hydrogen modules totalling over 30 m² of active area at UT Austin’s Hydrogen ProtoHub[iv].
Researchers from MIT (Massachusetts Institute of Technology) have developed a new, lower-carbon method of extracting hydrogen which uses sea water, aluminium cans and a small amount of a specific metal alloy. The process (which was initially proven at lab level last year) utilises the chemical reaction between aluminium and sea water to produce hydrogen.
However, the metal must first be treated given aluminium forms a thin but very resistant protective layer of aluminium oxide when exposed to air. Using a metal alloy to remove the outer layer leaves pure aluminium which exhibits exceptional reactivity with water. Aluminium atoms are then free to break down water molecules (H2O), forming aluminium oxide (or its hydrated forms such as boehmite) and, most importantly, releasing pure hydrogen gas (H2)[v].
MIT researcher Dr. Kombargi explains: "One of the main advantages of using aluminium is its energy density per unit volume. With a very small amount of aluminium fuel, it is theoretically possible to provide a significant portion of the energy needed to power a hydrogen vehicle."[vi]
Now the team have carried out a ‘cradle-to-grave’ study to prove the processes viability at scale. The team calculated the carbon emissions associated with acquiring and processing aluminium, reacting it with seawater to produce hydrogen, and transporting hydrogen to fuel stations, where drivers could tap into hydrogen tanks to power engines or fuel cell cars. They found that, from end to end, the new process could generate a fraction of the carbon emissions that is associated with conventional hydrogen production.
The findings, which were published in Cell Reports Sustainability in June, show that for every kilogram of hydrogen produced, the process would generate 1.45 kilograms of carbon dioxide over its entire life cycle. In comparison, fossil-fuel-based processes emit 11 kilograms of carbon dioxide per kilogram of hydrogen generated. This low-carbon footprint is on par with other proposed “green hydrogen” technologies, such as those powered by solar and wind energy, the researchers claim. In addition, Boehmite- the by-product produced in the process, is a valuable industrial raw material often used in the production of semiconductors, electronic components, catalysts, refractory materials, and as a filler in plastics and rubber.
[i] Grey, blue, green – the many colours of hydrogen explained | World Economic Forum
[ii] GHG emissions of hydrogen and its derivatives – Global Hydrogen Review 2024 – Analysis - IEA
[iii] SunHydrogen Demonstrates Commercial 1.92m² Hydrogen Module — SunHydrogen
[iv] SunHydrogen Launches >30m² Pilot Hydrogen System with UT Austin — SunHydrogen
[v] MIT: Hydrogen from aluminum and sea for clean energy | Karlobag
[vi] Ibid
Lauren has extensive experience as an analyst and market researcher in the digital technology and travel sectors. She has a background in researching and forecasting emerging technologies, with a particular passion for the Videogames and eSports industries. She joined the Critical Information Group as Head of Reports and Market Research at GRC World Forums, and leads the content and data research team at the Zero Carbon Academy. “What drew me to the academy is the opportunity to add content and commentary around sustainability across a wealth of industries and sectors.”
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