Low carbon hydrogen, produced by water electrolysis using renewable energy, stands out as a crucial energy vector for the decarbonization of industrial and transportation sectors. This chapter analyzes the safety risks associated with green hydrogen production, focusing on alkaline and proton exchange membrane (PEM) electrolysis systems, proposing mitigation measures based on technical standards, industrial best practices, and risk management tools. Through a mixed methodological approach—integrating an integrative literature review, comparative analysis of standards (ABNT NBR IEC 60079-10-1 and Petrobras N-2918), application of HAZOP and Bow Tie, and case studies in pilot units, critical challenges were identified, such as the high flammability of hydrogen, explosion risks from mixing with oxygen, material embrittlement (Hydrogen embrittlement—HE), and leaks in pressurized systems. The results revealed that the Petrobras N-2918 Standard, more conservative than the ABNT, offers practical guidelines for hazardous area classification, reducing risks in semi-confined environments. Additionally, the selection of corrosion-resistant materials, the implementation of early detection sensors, and the adoption of periodic inspection protocols (according to ASME B31.12-2023) are essential to ensure operational safety. It is concluded that the viability of green hydrogen depends on the integration of advanced technologies, robust regulations, and proactive risk management, ensuring its contribution to a safe and sustainable energy transition.

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Process Safety Aspects in Low Carbon Hydrogen Production via Electrolysis

  • Eugênio Paceli Carvalho da Silva,
  • Décio Yukishigue Fujimoto Júnior,
  • Victor Hugo Souza de Abreu

摘要

Low carbon hydrogen, produced by water electrolysis using renewable energy, stands out as a crucial energy vector for the decarbonization of industrial and transportation sectors. This chapter analyzes the safety risks associated with green hydrogen production, focusing on alkaline and proton exchange membrane (PEM) electrolysis systems, proposing mitigation measures based on technical standards, industrial best practices, and risk management tools. Through a mixed methodological approach—integrating an integrative literature review, comparative analysis of standards (ABNT NBR IEC 60079-10-1 and Petrobras N-2918), application of HAZOP and Bow Tie, and case studies in pilot units, critical challenges were identified, such as the high flammability of hydrogen, explosion risks from mixing with oxygen, material embrittlement (Hydrogen embrittlement—HE), and leaks in pressurized systems. The results revealed that the Petrobras N-2918 Standard, more conservative than the ABNT, offers practical guidelines for hazardous area classification, reducing risks in semi-confined environments. Additionally, the selection of corrosion-resistant materials, the implementation of early detection sensors, and the adoption of periodic inspection protocols (according to ASME B31.12-2023) are essential to ensure operational safety. It is concluded that the viability of green hydrogen depends on the integration of advanced technologies, robust regulations, and proactive risk management, ensuring its contribution to a safe and sustainable energy transition.