Abstract:
As a crucial energy carrier for the green transition, hydrogen holds great promise across large-scale applications including hydrogen fuel cell vehicles, hydrogen metallurgy, chemical synthesis, energy storage, and power generation. Its outstanding advantages, including high gravimetric energy density, source abundance, and zero-carbon combustion products, make it an indispensable component of global decarbonization strategies. However, its propensity for leakage, high flammability, and explosiveness present critical safety challenges that restrict industrial development. Unlike conventional fuels such as gasoline and natural gas, hydrogen possesses unique physical and chemical properties requiring dedicated safety considerations throughout its lifecycle. This paper systematically reviews the fundamental safety-related physicochemical properties of hydrogen, including its leakage behavior, diffusion characteristics, ignition sensitivity, and explosion potential. On this basis, an in-depth risk analysis is conducted across the four core links of the hydrogen energy chain: production, storage, transportation, and application. The risks associated with the production stage include excessive temperature during exothermic reactions, material failure due to hydrogen attack and corrosion, membrane component damage in electrolytic cells, and toxic gas leakage from reforming processes such as carbon monoxide release. The risks associated with the storage stage include hydrogen embrittlement of metallic containers under high-pressure service, overpressure caused by rapid filling or external heating, excessive static evaporation in cryogenic liquid hydrogen tanks, and metal hydride heat release during storage. The risks associated with the transportation stage include pipeline hydrogen embrittlement coupled with environmental factors such as low temperature and corrosive soil conditions, pressure fluctuations induced by valve operations and compressor cycling, and leakage accumulation in confined or poorly ventilated spaces. The risks associated with the application stage include high-pressure hydrogen leakage during refueling operations, accumulation in confined spaces such as underground garages and tunnels, and collision impacts on onboard storage systems in fuel cell vehicles, all of which may lead to catastrophic consequences if not properly managed. To address these multifaceted risks, this paper proposes systematic prevention and control strategies encompassing four complementary dimensions: material selection (including hydrogen-resistant alloys, advanced sealing materials, and composite overwrapped structures), process optimization (such as temperature and pressure control, inert gas purging, and controlled filling rates), intelligent monitoring (involving hydrogen-specific sensors, real-time leak detection, and automated alarm and shutdown systems), and spatial layout (including safety distances, ventilation design, and explosion-proof barriers). The study aims to deepen the scientific understanding of hydrogen safety throughout its lifecycle, provide systematic theoretical support for the safe utilization and risk management of hydrogen energy, and promote the safe, sustainable and high-quality development of the hydrogen energy industry. By integrating fundamental property analysis with practical risk prevention measures, this work contributes to bridging the gap between laboratory-scale safety research and industrial-scale safety engineering, ultimately facilitating the responsible deployment of hydrogen technologies in real-world applications while ensuring public and environmental safety. In conclusion, dialectical analysis of hydrogen safety characteristics as well as the outlook in future applications has been put forward.