Risks for upscaling of Power-to Hydrogen technologies based on water electrolysis for widespread incorporation with renewable energy resources

Abstract

This thesis examines safety risks associated with upscaling Power-to-Hydrogen technologies based on water electrolysis for integration with renewable energy systems. Safety hazards affecting hydrogen production facilities, personnel, and surrounding areas are identified, while economic aspects are excluded. A mixed-methods approach was applied, combining literature review, incident data analysis, and expert elicitation, supported by systematic risk assessment methods such as hazard and operability studies, bow-tie analysis, and hazard identification studies. The results indicate that hydrogen’s wide flammability range, low ignition energy, high diffusivity, and susceptibility to material embrittlement significantly increase safety risks compared to other industrial gases. Management deficiencies, material failures, and human factors are identified as the main contributors to hazardous events, and a multi-layered mitigation strategy including regulatory compliance, procedures, training, automation, and advanced detection and emergency response systems is recommended.