The transition to a low-carbon energy system presents an opportunity to repurpose decommissioned fossil fuel infrastructure for hydrogen production, aligning with circular economy principles. Retrofitting oil rigs, coal plants, and associated facilities can reduce decommissioning costs, minimize waste, and leverage existing energy assets. This approach not only accelerates the hydrogen economy but also supports regional economic transitions by preserving jobs and infrastructure.
Steam methane reforming (SMR) is a well-established hydrogen production method that could be adapted for retrofitted fossil fuel sites. By integrating carbon capture and storage (CCS), these facilities can produce low-carbon hydrogen while mitigating emissions. Existing natural gas pipelines connected to decommissioned plants may be repurposed to transport hydrogen or CO2 for storage. However, retrofitting SMR-CCS requires significant modifications, including new capture units, pipeline upgrades, and hydrogen-compatible materials to prevent embrittlement.
Offshore oil and gas platforms offer another pathway for hydrogen production through electrolysis. These structures can host electrolyzers powered by legacy grid connections or dedicated offshore wind farms. Seawater desalination units may be installed to provide purified water for electrolysis, while existing pipelines could transport hydrogen back to shore. Offshore electrolysis avoids land-use conflicts and benefits from higher wind capacity factors, improving efficiency. However, harsh marine conditions demand corrosion-resistant materials and robust safety systems to handle hydrogen’s flammability risks.
Coal plants, often located near water sources and grid infrastructure, are prime candidates for conversion to hydrogen hubs. Their high-voltage transmission lines can support electrolyzer arrays powered by renewable energy. Some coal facilities may transition to hydrogen combustion turbines, providing grid stability while reducing emissions. Retrofitting requires extensive modifications, such as replacing coal boilers with hydrogen-ready turbines and installing storage solutions like salt caverns or pressurized tanks.
Regulatory frameworks must evolve to address the repurposing of fossil fuel assets. Permitting processes for hydrogen projects vary by region, with some jurisdictions lacking clear guidelines for offshore electrolysis or blended hydrogen-natural gas pipelines. Safety standards for hydrogen storage and transport in retrofitted infrastructure also need harmonization. Policymakers must engage with industry stakeholders to establish certification schemes for low-carbon hydrogen, ensuring transparency and incentivizing investment.
Technical challenges include material compatibility, energy efficiency, and scalability. Hydrogen embrittlement can degrade pipelines and storage tanks not originally designed for hydrogen service, necessitating coatings or replacement with high-grade alloys. Electrolyzer efficiency remains a concern, particularly for alkaline and PEM systems, which require further advancements to compete with SMR-CCS on cost. Large-scale hydrogen storage solutions, such as repurposed salt caverns, must be validated for long-term reliability.
Community engagement is critical to the success of transitional energy hubs. Fossil fuel-dependent regions may resist changes due to job insecurity or mistrust in new technologies. Proactive outreach, workforce retraining programs, and local benefit agreements can foster acceptance. Demonstrating the economic advantages of repurposing—such as reduced decommissioning liabilities and new employment in hydrogen operations—helps build public support.
Case studies illustrate the potential of repurposing fossil fuel infrastructure. In the North Sea, several offshore oil platforms are being evaluated for electrolysis projects, leveraging existing subsea cables and pipelines. The Dutch PosHYdon pilot is testing offshore hydrogen production on a gas platform, integrating wind power and seawater desalination. In the U.S., the Petra Nova coal plant in Texas previously demonstrated CCS retrofitting, a model that could be adapted for hydrogen. Australia’s Latrobe Valley is exploring coal-to-hydrogen transitions, using brown coal gasification with CCS while piloting renewable-powered electrolysis.
The circular economy aspect extends beyond infrastructure repurposing. By-products from hydrogen production, such as oxygen from electrolysis, can be utilized in industrial processes or wastewater treatment. Waste heat from SMR or electrolysis may support district heating systems, improving overall energy efficiency. Decommissioned fossil fuel sites can also host renewable energy installations, creating hybrid systems that optimize land use.
Economic viability depends on scaling technologies and reducing costs. Electrolyzer capital expenses must decline further to compete with fossil-based hydrogen, while CCS costs require reduction through economies of scale. Government incentives, such as tax credits or grants for retrofits, can bridge the gap during the transition. Private sector collaboration is essential, with energy companies, electrolyzer manufacturers, and engineering firms partnering to standardize retrofitting processes.
The integration of hydrogen into existing energy systems must be carefully planned. Blending hydrogen into natural gas grids offers a transitional strategy but faces limits due to pipeline material constraints and end-use appliance compatibility. Dedicated hydrogen pipelines, converted from natural gas lines, may be necessary for high-volume transport. Storage infrastructure, such as repurposed salt caverns, must be strategically located near demand centers to ensure supply stability.
Looking ahead, repurposing fossil fuel infrastructure for hydrogen production can play a pivotal role in achieving net-zero targets. By leveraging existing assets, the energy sector can reduce transition costs, accelerate deployment, and support affected communities. Continued innovation in electrolysis, CCS, and materials science will enhance feasibility, while robust policies and stakeholder collaboration will drive large-scale adoption. The circular economy model ensures that legacy energy infrastructure contributes to a sustainable future rather than becoming stranded liabilities.
In summary, the conversion of decommissioned fossil fuel sites into hydrogen hubs presents a pragmatic solution for the energy transition. Retrofitting SMR with CCS or deploying offshore electrolysis capitalizes on existing infrastructure while addressing technical and regulatory hurdles. Case studies demonstrate the potential, but widespread adoption requires cost reductions, policy support, and community buy-in. As the hydrogen economy matures, repurposing will be a key strategy in bridging the gap between legacy systems and a decarbonized future.