Risks, their Occurrence and their Prevention through the Implementation of Hydrogen in the Energy-Intensive Industry

Hydrogen shows great promise for reduction the CO2-emission of production in energy-intensive processes. Due to the immense amount of energy required to melt raw materials, for example in glass and aluminum production, switching from natural gas to (green) hydrogen or mixing the two fuels would significantly impact decarbonization and emissions. However, there are plant and process risks associated with the implementation of hydrogen that need to be considered. This applies to hydrogen storage, hydrogen distribution, and the melting furnace. It is also unclear whether and to what extent hydrogen affects the quality of the product.
Against this backdrop, the question arises about how the decarbonization of energy-intensive processes requires attention on the plant and process side. To summarize the existing knowledge, the use of hydrogen in the energy-intensive industry, differences to the current state of the art and risks are first shown. A literature review on hydrogen damage, its mechanisms, and phenomena is carried out to explain the interaction between hydrogen and certain materials. In the next step, material databases and experimental test results for materials relevant to such industries will be used to compile assessments of their compatibility. To ensure the safety of people, machines, and products in the event of a fault, measurement options for hydrogen leaks are discussed and their operating conditions, advantages, and disadvantages are described. Finally, recommendations for the glass industry are given to ensure plant and process safety as well as economic efficiency.