Hydrogen infrastructure


A hydrogen infrastructure is the infrastructure of points of hydrogen production, truck and pipeline transport, and hydrogen stations for the distribution and sale of hydrogen fuel, and thus a crucial prerequisite before a successful commercialization of fuel cell technology.
Hydrogen stations which are not situated near a hydrogen pipeline get supply via compressed hydrogen tube trailers, liquid hydrogen trailers, liquid hydrogen tank trucks or dedicated onsite production. Pipelines are the cheapest way to move hydrogen over long distances but must be designed to withstand the leakage and steel embrittlement caused by the hydrogen molecule. Hydrogen gas piping is routine in large oil-refineries, because hydrogen is used to hydrocrack fuels from crude oil. The IEA recommends existing industrial ports be used for production and natural gas pipelines for transport, international co-operation and shipping.
South Korea and Japan, which as of 2019 lacked international electrical interconnectors, were investing in the hydrogen economy. In March 2020, the Fukushima Hydrogen Energy Research Field was opened in Japan, claiming to be the world's largest hydrogen production facility. Much of the site is occupied by a solar array; power from the grid is also used for electrolysis of water to produce hydrogen fuel.

Network

Hydrogen highways and stations

A hydrogen highway is a chain of hydrogen-equipped filling stations and other infrastructure along a road or highway which allow hydrogen vehicles to travel.
Hydrogen stations that are not situated near a hydrogen pipeline get deliveries of hydrogen tanks via compressed hydrogen tube trailers, liquid hydrogen trailers, liquid hydrogen tank trucks or dedicated onsite production. Governments have supported some initiatives to expand hydrogen fuel infrastructure in the US state of California, in some member states of the European Union, Japan and elsewhere.

Hydrogen pipeline transport

Hydrogen pipeline transport may be used to connect the point of hydrogen production or delivery of hydrogen with the point of demand. According to a 2024 research report, the United States had 1,600 miles of hydrogen pipelines, and the global total stood at 2,800 miles. The World Economic Forum, in December 2023, however, estimated that Europe had approximately 1,600 kilometers of hydrogen pipelines.
Hydrogen embrittlement occurs primarily with 'diffusible' hydrogen, i.e. atoms or ions. Hydrogen gas, however, is molecular, and there is a significant energy barrier to splitting it into atoms.

Hydrogen production plants

98% of hydrogen production uses the steam reforming method. Methods such as electrolysis of water are also used. The world's largest facility for producing electrolytic hydrogen fuel is claimed to be the Fukushima Hydrogen Energy Research Field, a 10MW-class hydrogen production unit, inaugurated on 7 March 2020, in Namie, Fukushima Prefecture. The site occupies 180,000 square meters of land, much of which is occupied by a solar array; but power from the grid is also used to conduct electrolysis of water to produce hydrogen fuel.

Hydrogen pipeline transport

Hydrogen may be transported through pipes.

History

Hydrogen pipeline transport is sometimes used to transport hydrogen from the point of production or delivery to the point of demand. Although hydrogen pipeline transport is technologically mature, most hydrogen is produced in the place of demand, with an industrial production facility every

Piping

For process metal piping at pressures up to, high-purity stainless steel piping with a maximum hardness of 80 HRB is preferred. This is because higher hardnesses are associated with lower fracture toughness so stronger, higher hardness steel is less safe.
Composite pipes are assessed like:
  • carbon fiber structure with fiberglass overlay .
  • perfluoroalkoxy.
  • polytetrafluoroethylene
  • fluorinated ethylene propylene .
  • carbon-fiber-reinforced polymers
Fiber-Reinforced Polymer pipelines and reinforced thermoplastic pipes are researched.
Carrying hydrogen in steel pipelines does not lead to hydrogen embrittlement. Hydrogen is typically stored in steel cylinders without problems.

Infrastructure

  • 2024: USA – of low pressure hydrogen pipelines
  • 2024: Europe – of low pressure hydrogen pipelines.

    Hydrogen highway

A hydrogen highway is a chain of hydrogen-equipped public filling stations, along a road or highway, that allows hydrogen powered cars to travel. William Clay Ford Jr. has stated that infrastructure is one of three factors that hold back the marketability of fuel cell cars.

Supply issues, cost and pollution

Hydrogen fueling stations generally receive deliveries of hydrogen by tanker truck from hydrogen suppliers. An interruption at a hydrogen supply facility can shut down multiple hydrogen fueling stations. A hydrogen fueling station costs between $1 million and $4 million to build.
As of 2019, 98% of hydrogen is produced by steam methane reforming, which emits carbon dioxide. The bulk of hydrogen is also transported in trucks, so pollution is emitted in its transportation.

Hydrogen station

A hydrogen station is a storage or filling station for hydrogen fuel. The hydrogen is dispensed by weight. Two filling pressures are in common use: H70 or 700 bar, and the older standard H35 or 350 bar., around 550 filling stations were available worldwide. According to H2stations.org by Ludwig-Bölkow-Systemtechnik, as of the end of 2023, there were 921 hydrogen refueling stations globally, although this number clearly conflicts with those published by AFDC. The distribution of these stations is highly uneven, with a concentration in East Asia, particularly in China, Japan and South Korea; Central Europe and California in the United States. Other regions have very few, if any, hydrogen refuelling stations.

Delivery methods

Hydrogen fueling stations can be divided into off-site stations, where hydrogen is delivered by truck or pipeline, and on-site stations that produce and compress hydrogen for the vehicles.

Types of recharging stations

Home hydrogen fueling station

Home hydrogen fueling stations have been offered for purchase. A model that could produce 12 kilograms of hydrogen per day sold for $325,000 in 2019.
Solar powered water electrolysing hydrogen home stations are composed of solar cells, power converter, water purifier, electrolyzer, piping, hydrogen purifier, oxygen purifier, compressor, pressure vessels and a hydrogen outlet.

Disadvantages

Volatility

Hydrogen fuel is hazardous because of its low ignition energy, high combustion energy, and because it easily leaks from tanks. Explosions at hydrogen filling stations have been reported.

Supply

Hydrogen fuelling stations generally receive deliveries by truck from hydrogen suppliers. An interruption at a hydrogen supply facility can shut down multiple hydrogen fuelling stations due to an interruption of the supply of hydrogen.

Costs

There are far fewer Hydrogen filling stations than gasoline fuel stations, which in the US alone numbered 168,000 in 2004. Replacing the US gasoline infrastructure with hydrogen fuel infrastructure is estimated to cost a half trillion U.S. dollars. A hydrogen fueling station costs between $1 million and $4 million to build. In comparison, battery electric vehicles can charge at home or at public chargers. As of 2025, there are more than 70,000 public charging stations in the United States, with more than 200,000 chargers. A public Level 2 charger, which comprise the majority of public chargers in the US, costs about $2,000, and DC fast chargers, of which there are more than 55,000 in the U.S., generally cost between $30,000 and $150,000 for equipment and installation;

Freezing of the nozzle

During refueling, the flow of cold hydrogen can cause frost to form on the dispenser nozzle, sometimes leading to the nozzle becoming frozen to the vehicle being refueled.

Locations

H2stations.org tracks global hydrogen filling stations and publishes statistics and a map. They count a total of 980 hydrogen fuelling stations in operation worldwide as of the end of 2024.

Asia

In 2019, there were 178 publicly available hydrogen fuel stations in operation. By the end of 2024, there were more than 550 in operation in Asia, including about 200 in China.
, there were 167 publicly available hydrogen fuel stations in operation in Japan. In 2012 there were 17 hydrogen stations, and in 2021, there were 137 publicly available hydrogen fuel stations in Japan.
In 2019, there were 33 publicly available hydrogen fuel stations in operation in South Korea. In November 2023, however, due to hydrogen supply problems and broken stations, most fueling stations in South Korea offered no hydrogen. 41 out of the 159 hydrogen stations in the country were listed as open, and some of these were rationing supplies of hydrogen.

Europe

In 2019, there were 177 stations in Europe. According to H2stations.org, there were nearly 300 hydrogen refuelling stations in Europe by the end of 2024.
there were 105 hydrogen fuel stations in Germany, there were 5 publicly available hydrogen fuel stations in France, 3 publicly available hydrogen fuel stations in Iceland, one publicly available hydrogen fuel station in Italy, 4 publicly available hydrogen fuel stations in The Netherlands, 2 publicly available hydrogen fuel stations in Belgium, 4 publicly available hydrogen fuel stations in Sweden, 3 publicly available hydrogen fuel stations in Switzerland and 6 publicly available hydrogen fuel stations in Denmark. Everfuel, the only operator of hydrogen stations in Denmark, announced in 2023 the closure of all of its public hydrogen stations in the country.
there were 2 publicly available hydrogen fuel stations in Norway, both in the Oslo area. Since the explosion at the hydrogen filling station in Sandvika in June 2019, the sale of hydrogen cars in Norway has halted. In 2023, Everfuel announced the closure of its two public hydrogen stations in Norway and cancelled the opening of a third. In 2024 Shell discontinued its hydrogen fuel projects in Norway.
there were 11 publicly available hydrogen fuel stations in the United Kingdom, but as of 2023, the number decreased to 5. In 2022, Shell closed its three hydrogen stations in the UK,