Hydrogen production from flare gas: a dual opportunity to turn emissions into energy - a prospective review

Gas flaring, practiced for over 160 years in oil production, has become a critical environmental and economic issue; wasting substantial resources and accelerating climate change. Each year, nearly 148 billion cubic meters of natural gas are burned off globally, emitting methane (CH4), black carbon, and volatile organic compounds. These pollutants contribute to respiratory health problems, increased cancer risks, and extensive environmental degradation, especially impacting communities near flaring sites. If harnessed, this flared gas has the potential to fuel substantial energy needs on a national or even continental scale. This review explores the transformative potential of converting flare gas into low-carbon hydrogen (H2), a process that addresses both greenhouse gas (GHG) reduction and clean energy generation. Examining advanced scientific and technological pathways, this study discusses the thermodynamics, catalyst development, and gas purification challenges necessary for efficient H2 production. Economic considerations are also assessed, with attention to cost-benefit analyses, carbon markets, and examples where H2 generation from flare gas has proven financially viable and sustainable. Case studies showcase diverse implementations worldwide, providing a blueprint for scaling H2 production from flaring operations. This review also highlights the prospects of flare gas-to-H2 conversion as a critical pathway for advancing sustainable energy and decarbonization innovations. Combinedly, it offers a valuable resource for researchers, industry leaders, and policymakers, advancing sustainable H2 production from flare gas and supporting critical efforts in global decarbonization.