Operations

Green Hydrogen: How It's Made and Why It Matters

How electrolysers produce green hydrogen, where it fits in the energy transition, and the real economics vs blue and grey.

Green hydrogen is hydrogen produced by electrolysis using renewable electricity. It is expensive today but potentially transformative for hard to abate sectors. This guide covers the technology, economics, and where green hydrogen actually makes sense.

The colours of hydrogen

ColourSourceEmissions
GreenElectrolysis with renewable electricityNear zero
BlueNatural gas reforming with CCSLow if CCS captures well
GreyNatural gas reformingHigh (10 kg CO2 per kg H2)
PinkElectrolysis with nuclear electricityLow
TurquoiseMethane pyrolysis producing solid carbonLow

How electrolysis works

Electricity splits water (H2O) into hydrogen (H2) and oxygen (O2). Two dominant electrolyser types: alkaline (mature, lower cost) and PEM (proton exchange membrane, higher efficiency, more flexible). Emerging: solid oxide (high efficiency, high temperature).

Current scale

~1 GW
green hydrogen electrolyser capacity 2024
Over 500 GW
announced pipeline through 2030
~1%
of global hydrogen currently green

Where green hydrogen makes sense

Key insight. Green hydrogen is not the answer for everything. It makes most sense for hard to abate sectors: fertiliser, steel making, refining, long duration storage, aviation and shipping fuels. For applications where direct electrification works (cars, home heating), electrons beat green hydrogen on cost and efficiency.
ApplicationGreen H2 case
Fertiliser (ammonia)Strong. Replaces grey H2 in existing use.
Steel makingStrong. Direct reduction of iron.
RefiningExisting hydrogen use in refineries.
Long duration storageOnly viable long duration option in some scenarios.
Aviation and shipping fuelsVia synthetic fuels or ammonia.
Passenger carsWeak. Batteries win.
Home heatingWeak. Heat pumps win.

Cost trajectory

Green hydrogen currently USD 4 to 8 per kg. Grey hydrogen USD 1 to 2 per kg. Green must fall to USD 2 to 3 per kg to be broadly competitive. Cost falls with renewable electricity price and electrolyser cost. See IEA Global Hydrogen Review 2024.

Cost breakdown

ComponentShare
Renewable electricity60 to 70%
Electrolyser CAPEX20 to 30%
Water treatmentSmall
Compression and storage5 to 10%
OPEX (excluding electricity)Small

Hydrogen storage

Hydrogen storage is hard because of low density. Options include compressed (700 bar), liquid (very cold), salt caverns, pipelines, and chemical carriers (ammonia, LOHC). See our companion article on hydrogen storage challenges.

Policy support

US IRA production tax credit up to USD 3 per kg. EU Hydrogen Bank. UK, Germany, Japan, Korea national strategies. Aggressive policy driving investment.

Contemporary challenges

Common trap. Announced hydrogen projects greatly exceed final investment decisions. Many projects will not materialise. Actual green hydrogen deployment is running behind announced pipeline. Cost competitiveness is a real constraint.

Leading regions

RegionFocus
Middle EastSolar based export
ChileWind based export
AustraliaExport projects
EuropeIndustrial decarbonisation
USIRA driven hub development
ChinaDomestic industrial applications

Where green hydrogen is going

  • Continued electrolyser cost reduction.
  • Industrial project deployment.
  • Ammonia based hydrogen trade emerging.
  • Steel decarbonisation pilots scaling.
  • Airline sustainable aviation fuel from hydrogen.
  • Reduced expectations for consumer applications.

Frequently asked questions

Is green hydrogen renewable?

Yes when made with renewable electricity.

How expensive is it?

USD 4 to 8 per kg currently. Grey is USD 1 to 2 per kg.

What is best use?

Existing hydrogen users (fertiliser, refining, steel). Not consumer cars or heating.

Can it replace natural gas?

Limited applications. Direct electrification usually better where possible.

Is it clean to burn?

Yes. Only water as byproduct.

How is it stored?

Compressed, liquid, salt cavern, or chemical carrier.

Are cars a good use?

Generally no. Batteries better for most use cases.

What about aviation?

Possibly for long haul via synthetic fuels.

Are hydrogen trains viable?

For some rural routes. Battery trains often better on major lines.

Where can I read more?

IEA Global Hydrogen Review, IRENA, national strategies.

Summary

Green hydrogen is real technology growing rapidly on policy support. Cost is still high but falling. Best use cases are hard to abate sectors like fertiliser, steel, and refining, not consumer cars or heating. Storage remains challenging. Deployment is running behind announced pipeline but scaling. The next decade will show whether green hydrogen fulfils its industrial promise.

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