Advancing hydrogen safety in production, storage, and utilization: insights into backfire phenomena, combustion behavior, and explosion mitigation strategies

Hydrogen is emerging as a vital component of the renewable energy landscape due to its clean and sustainable characteristics. However, its widespread adoption faces significant challenges in production, storage, safety, and transportation due to its unique chemical properties, such as high diffusivity, low ignition energy (0.02 mJ), and flammability 4–75% by volume in air and 4–94% by volume in oxygen. Currently, Steam Methane Reforming (SMR) is the dominant hydrogen production method, which demands high temperatures (700–1000 °C for primary and 1000–11500 °C for secondary reformation) and energy input (142–155 MJ per kg of H 2 ), along with leak-proof and explosion-resistant infrastructure. Ensuring proper ventilation, gas detection systems, and automated shutdown mechanisms is essential to mitigate risks. Storage remains another major concern, involving high-pressure systems (350–700 bar) that require ultra-high-strength composites to prevent rupture. Cryogenic storage at − 253 °C faces boil-off issues, while solid-state storage using metal hydrides offers a promising alternative. Transportation of hydrogen through pipelines, pressurized containers, and cryogenic tanks also poses challenges, requiring hydrogen-compatible materials and strict adherence to safety standards. Establishing robust emergency response protocols, including venting and isolation procedures, is vital for safe hydrogen handling from production to end-use. This study aims to understand hydrogen generation safety, storage, and transportation and to explore different regulation policies. Network visualization identified "hydrogen storage," "safety," and "security" as the most frequently used keywords. Country-wise analysis revealed that China leads in publication volume, followed by the USA and Germany. Overall, improvements in materials, monitoring technologies, and regulatory norms are necessary to enhance safety. To promote hydrogen’s role in the future of energy, further studies should concentrate on enhancing leak detection, storage longevity, and transportation infrastructure.