Industrial sectors such as mining and manufacturing face some of the toughest decarbonisation challenges. High power demand, remote locations, heavy loads, heat requirements and harsh operating conditions make them hard to electrify solely with batteries. This is where hydrogen fuel cells are emerging as a powerful solution, providing reliable, zero‑emission power and heat, especially in applications that run 24/7 or in hard‑to‑reach environments.
Why hydrogen fuel cells are gaining traction in industry
Hydrogen fuel cells convert hydrogen into electricity (and heat) through a chemical reaction. This delivers several advantages in industrial settings:
- Continuous power generation capability when hydrogen is supplied, not subject to long charging times like batteries
- Suitability for remote, off‑grid, harsh or heavy‑duty applications, where grid extension or battery recharging are difficult or costly (learn more about fuel cells for off-grid applications here)
- The co‑generation potential: the heat produced can be reused in industrial processes or facility heating
- Zero emissions at point of use
The UK Hydrogen Strategy identifies hydrogen as a key technology to decarbonise these sectors, including industrial heat and power systems. It also offers funding and incentives for industrial fuel switching to hydrogen and low‑carbon fuels.
Manufacturing applications of hydrogen fuel cells
In manufacturing sites – whether for chemicals, metals, food, pharmaceuticals or heavy engineering – the demand for electricity and process‑heat makes hydrogen fuel cells especially attractive.
Key application benefits include:
- Reliable onsite baseload power and standby capability: some fuel cell installations act as micro‑grids, offering resilience in grid outages.
- Combined heat and power (CHP) opportunities: the waste heat generated by fuel cells can replace fossil‑fuel boilers or industrial heaters.
- Reduced Scope 1 emissions: plants that directly combust fuel contribute heavily to organisational emissions. Switching to hydrogen fuel cells can significantly reduce this.
- Alignment with industrial funding streams: the UK’s Industrial Energy Transformation Fund (IETF) supports industrial energy efficiency and fuel‑switching; hydrogen fuel cell systems qualify under these schemes.
For further reading on stationary fuel cell applications, read our article on the top 4 applications of stationary fuel cells.
Example scenario: A large manufacturing plant installs a multi‑megawatt fuel cell system. During normal operation it runs in parallel with the grid; during grid interruption it seamlessly transitions to standalone mode. The waste heat is routed to pre‑heat drying tunnels, reducing natural gas use. Over time the plant saves on energy costs, improves uptime and meets tighter emissions regulation.
For more on backup power benefits, see our article: 6 advantages of hydrogen fuel cells for backup power.
Advantages of hydrogen fuel cells for mining and heavy industry
Mining operations and heavy industry (steel, cement, minerals) often operate in remote locations or use heavy‑duty machinery. Hydrogen fuel cells offer distinct advantages here:
- Remote power generation: Sites far from grid connections can benefit from fuel cells with hydrogen delivered by cylinder, tube‑trailers or via onsite hydrogen generation. For further reading on this, see How Fuel Cells Can Power Remote and Off-Grid Communities.
- Robust operation under harsh conditions: Fuel cells have fewer moving parts than combustion engines, potentially reducing maintenance in abrasive or dusty environments.
- Heat recovery: Many mining and heavy‑industry processes demand thermal energy (for smelting, drying, ore processing). Fuel cell waste heat can often be repurposed.
- Diesel replacement: Diesel generators are still common in mining sites. Hydrogen fuel cell systems replace them with zero‑tail‑pipe‑emission alternatives, with lower vibration and noise (beneficial for underground or enclosed operations).
As the UK’s hydrogen infrastructure is still developing, it’s important to carefully plan how hydrogen is delivered, stored, and safely used on industrial sites. The legal framework is also changing. For example, recent updates to the Gas Act under the Energy Act 2023 now formally cover hydrogen transport and storage.
Future outlook and scaling in industrial systems
The future of hydrogen fuel cells in industrial environments is promising. As technologies mature and costs fall, we can expect:
- Increased adoption in manufacturing and mining, especially where fossil fuel heat is being phased out.
- Growth of modular fuel cell plants for industrial sites, with both power and heat responsibilities.
- Tighter coupling between hydrogen generation, storage and fuel cells in integrated industrial clusters.
- More industrial incentives and policy support globally and in the UK for fuel switching and low‑carbon fuels.
If you’d like to explore how hydrogen fuel cell systems could work at your site, whether in manufacturing, mining or another industrial energy‑intensive process, get in touch today and we’ll discuss your requirements.
FAQs
What are hydrogen fuel cells used for?
They’re used to provide clean, continuous power and heat for industrial applications. Common uses include powering manufacturing facilities, mines, backup systems, and remote operations where grid access is limited or unreliable. They can replace diesel generators, support combined heat and power (CHP) systems, or act as base load generators.
Are hydrogen fuel cells suitable for off-grid industrial sites?
Yes. Industrial hydrogen fuel cells are ideal for off-grid or remote sites, such as mines or rural factories. They can operate independently of the grid and be supplied with hydrogen via tube trailers, onsite electrolysers, or high-pressure cylinders. Read more in Fuel Cells for Off-Grid Applications.
Can fuel cells supply both electricity and heat for industrial processes?
Yes. Many hydrogen fuel cells support combined heat and power (CHP) applications, making them well-suited for industries that need both electrical energy and thermal energy (e.g. for drying, heating, or steam processes).
What are the environmental benefits of fuel cells?
Fuel cells produce zero harmful emissions at the point of use when run on green hydrogen (no CO₂, NOₓ, or particulates). This helps reduce Scope 1 emissions in manufacturing and mining operations and supports compliance with decarbonisation targets.
What size systems are available for industrial use?
Fuel cells can scale from tens of kilowatts to multi-megawatt systems, making them flexible for a wide range of applications – from powering a single line in a factory to an entire processing plant or mining site.
How is hydrogen supplied and stored for industrial use?
Hydrogen can be delivered in cylinders, bulk tube trailers, or produced onsite via electrolysis. Storage is usually in high-pressure tanks with appropriate safety and regulatory compliance. Site-specific solutions depend on energy demand, geography, and hydrogen supply chain maturity.