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Industrial automation solutions for sustainable hydrogen production

Enabling reliable hydrogen production

Across industries worldwide, the transition towards lower-carbon energy systems is reshaping how energy is produced, stored and used. Green hydrogen production is increasingly recognised as a key enabler of decarbonisation — supporting industrial performance, operational reliability and long-term productivity.

As hydrogen technologies move from pilot projects to industrial-scale deployment, stable and efficient operation becomes essential. From hydrogen production to downstream processes, reliable automation, precise control and robust system design are critical to ensure long-term, safe and efficient operation.

Overcoming automation challenges in hydrogen production

At SMC, we understand the technical and operational requirements of hydrogen applications. With decades of experience in industrial automation, we support hydrogen projects across the entire hydrogen value chain with solutions designed to enhance reliability, efficiency and system stability.

The hydrogen value chain connects renewable energy with industrial and energy end-use applications. From hydrogen production to storage, transportation and end use, each stage must operate with stable performance, safe handling and precise process control to enable large-scale deployment.

As green hydrogen production scales from pilot projects to industrial deployment , operators are facing critical challenges:

  • Operational availability – Maximising system uptime and operational stability
  • Safe hydrogen production – Mitigating risks and ensuring functional safety 
  • Energy efficiency – Minimising energy losses across cooling and auxiliary systems.
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Automation Across the Hydrogen Value Chain

The hydrogen value chain connects renewable energy with real-world industrial and energy applications. From hydrogen production through to final use, each stage must operate reliably and efficiently to ensure hydrogen can be deployed at scale as a clean energy carrier.

At SMC, we support hydrogen projects across all four stages — production, storage, transportation and use of hydrogen — with advanced automation and fluid control solutions designed to ensure stable and efficient operation.

While our technologies are present throughout the entire process, our primary focus is on hydrogen production, where precise control, reliable cooling, pressure management and fluid handling are critical to plant performance. By concentrating on this most automation-intensive stage, we help customers build reliable and scalable hydrogen systems that are ready for industrial deployment.

  • Production

  • Storage

  • Transport

  • Use

Production

Hydrogen production equipment (water electrolysis)

Water electrolysis splits water into hydrogen and oxygen using renewable electricity — the core of green hydrogen generation.

Reliable cooling, precise valve actuation, air treatment and robust fluid handling systems are essential to ensure stable operation and optimise overall plant performance.

Hydrogen production equipment (water electrolysis)

Storage

Stored with hydrogen storage alloys

Hydrogen must be held safely under controlled conditions before distribution or use. Storage systems demand secure pressure environments and materials compatible with hydrogen embrittlement to ensure operational reliability at scale. 

Stored with hydrogen storage alloys

Transport

Transport by trailers / gas cylinder racks

Transporting hydrogen often via specialised trailers or tube rack systems — requires stable flow management, secure pressure containment and monitoring throughout the distribution chain to maintain safety and integrity. 

Transport by trailers / gas cylinder racks

Use

Hydrogen boilers & CO₂-free vapour

At the point of use, hydrogen serves industrial boilers or energy applications, producing clean heat or CO₂-free vapour. Precise delivery control and safe integration into downstream systems are key to performance.

Hydrogen boilers & CO₂-free vapour

Hydrogen production and balance of plant solutions

Hydrogen production through water electrolysis is a highly controlled industrial process that converts electrical energy into hydrogen using water as the primary input. To ensure stable, efficient and continuous operation, the electrolysis system relies on a combination of power electronics, water treatment, thermal management and precise control of gases and auxiliary utilities.

Beyond the electrolyser itself, the surrounding Balance of Plant plays a decisive role in overall system performance. Power rectification, cooling, pure water supply, instrument air quality and gas handling must operate in harmony to maintain efficiency, safety and hydrogen purity. Any instability in these supporting systems can directly affect production efficiency and equipment lifetime.

SMC supports hydrogen production systems with automation, fluid control and thermal management solutions designed to enhance reliability and operational stability. By providing precise control of air, water and gases, as well as efficient cooling and monitoring, SMC helps ensure that hydrogen production processes run smoothly, safely and efficiently from start-up to full-scale operation.

Key technologies supporting hydrogen production

Cooling

Valve actuation and control

Air treatment and pressure control

Fluid control and piping equipment

SMC’s Solutions to realise a future hydrogen society

Get detailed information about SMC products and technologies supporting hydrogen production systems.

Click in the picture bellow for more information.

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Hydrogen production FAQs and technical insights

How can hydrogen production efficiency be improved in electrolysis systems?

Hydrogen production efficiency depends heavily on the stability of supporting systems such as cooling, pressure control and fluid management. Maintaining optimal operating temperatures, ensuring precise valve actuation and providing clean, stable instrument air all help reduce energy losses and improve overall system performance. Reliable component selection and proper system design are also essential to maximise efficiency and minimise downtime.

Why is cooling critical in hydrogen production plants?

During electrolysis, significant heat is generated by rectifiers, electrolysers and auxiliary equipment. Without effective thermal management, excessive temperatures can reduce efficiency, aggravate component degradation and compromise operational stability. Using dedicated industrial thermo-chillers helps maintain stable operating conditions and ensure consistent hydrogen production.

What are the most common causes of downtime in hydrogen production systems?

Unplanned downtime can be linked to failures in valve actuation, cooling systems, air quality or fluid handling components. Contaminated instrument air, unstable temperatures or unreliable valve control can disrupt the process. Using high-quality, reliable components and ensuring proper air preparation and fluid control can significantly improve system availability.

How does instrument air quality affect hydrogen production performance?

Instrument air is used to actuate valves and control key process functions. If the compressed air contains moisture, oil or particles, it can cause component wear, malfunction and unreliable operation. Proper air treatment and pressure regulation ensures stable and safe control of the hydrogen production process.

What components are essential for reliable hydrogen production systems?

Hydrogen production systems rely on several critical technologies, including:

  • Cooling and temperature control systems
  • Valve actuation and control components
  • Air treatment and pressure regulation equipment
  • Fluid control and high-purity piping solutions.

These components ensure safe, efficient and continuous operation across the hydrogen production process.

Start optimising your hydrogen production system today

SMC combines industrial expertise and advanced component technologies to support hydrogen production applications. Our team can help you identify the right solutions to improve efficiency, reliability and operational performance.

Contact us to speak with a hydrogen application specialist.

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