Digitally transforming hydrogen production from design through operations
May 07, 2025
As the world accelerates toward a net-zero emissions future, clean hydrogen is emerging as a vital clean energy source across various sectors. McKinsey & Company predicts that by 2050, clean hydrogen demand could account for up to 73 to 100% (125 to 585 Mtpa) of total hydrogen demand. That said, there are several challenges that must be addressed before hydrogen production can be scaled up to meet energy transition goals. Emerging technologies and data management systems hold great potential to speed up the process; however, challenges remain.
Plant data management: an opportunity for improvement
Hydrogen production plants are complex, capital-intensive operations requiring significant investments in infrastructure and technology. From electrolysers and storage tanks to fuel systems and pipeline networks, these facilities are a complex web of interconnected systems comprising vast amounts of technical data. This data is crucial for efficient operations and maintenance, yet often remains underutilised due to challenges in data management and interoperability. For example, during data-handovers, large volumes of documents and data are transferred from stakeholders, such as engineering and procurement teams to operational staff. These documents, often a mix of 2D drawings, 3D models, and other technical files, are typically stored in disparate systems, making it difficult to organize, validate, and verify the information. Furthermore, the lack of consistency in asset information across different plants exacerbates this problem. Facilities are often designed using various standards and tools, with little consideration for the long-term value of project data.
A strong digital foundation enables integration across design, build, and operational processes – paving the way for a profitable hydrogen economy at scale.
Opportunities from a solid digital foundation
Establishing a solid digital foundation offers numerous benefits across the hydrogen production lifecycle. It enables the consolidation of data from various sources, including equipment design, plant design, and operations and maintenance data. By integrating this data into a cohesive system, hydrogen producers can improve collaboration across the supply chain, reduce errors and enhance decision-making.
A key aspect of digital transformation is creating a comprehensive digital twin – a smart, digital representation of all physical assets and processes within a hydrogen plant. By establishing a digital twin, hydrogen producers gain a single source of truth and an aggregated view of all relevant design, operational, and regulatory information. This approach is crucial for optimising performance across the asset lifecycle, from initial design to decommissioning.
The value of connecting systems of systems
Integrating digital technologies facilitates the connection of "systems of systems," where technical and business information is authored in native systems and connected to a central information backbone. This connection enhances awareness across the lifecycle, improves change management, and enables proactive issue resolution. Additionally, cloud-based solutions offer hydrogen producers the ability to adopt new technologies quickly and achieve digital lifecycle excellence.
Building a digital-first operating model
Finally, the importance of clean hydrogen in reducing emissions is clear, yet it eludes many. Governments and organisations have made giant commitments. But are we ready to turn this vision into reality? Market volatility and regulatory changes can be difficult to anticipate. Organisations with a digital-first strategy will be better equipped to mitigate risks and gain a significant competitive advantage. What’s needed is for organisations to move from “embracing digital” to “becoming digital”. It’s a journey that begins with connecting the entire lifecycle of your capital assets, from design through operations.
Our clients in energy, chemicals and infrastructure businesses have embraced this journey approach with resounding success. It’s not only helping them streamline processes and reduce costs in the short term, but also improve efficiency over the lifetime of their plants. Explore Siemens hydrogen solutions.
