Welding plays a vital role in modern infrastructure, from construction sites and equipment maintenance to pipeline installation. Yet, approximately 30 per cent of this work takes place off-site—often in remote or undeveloped areas where access to grid electricity is limited. As a result, most welding operations rely on diesel generators for power, contributing significantly to CO₂ emissions and local air pollution.
Now, a Spanish hydrogen technology company is working to change that.
COOLERGY, a recognised leader in hydrogen-based energy solutions, has introduced an innovative mobile hydrogen fuel cell generator called the Coolergizer, designed specifically to make off-grid welding cleaner and more sustainable.
A Cleaner Power Alternative for Field Welding
The Coolergizer is a compact but powerful solution: it delivers a maximum output of 80 kW, housed on a 3 x 1.5 metre trailer, and offers an onboard energy capacity of 360 kWh. When connected to external hydrogen cylinders, its capacity effectively becomes unlimited. The system weighs approximately 600 kg and is fully mobile, allowing easy transportation to and between job sites.
Unlike diesel generators, the Coolergizer emits no greenhouse gases during operation—only distilled water. This makes it a game-changer for environmentally conscious industries looking to reduce their carbon footprint.
Proven Impact: The H2med Hydrogen Pipeline
To demonstrate the potential environmental benefits of green welding, COOLERGY refers to the H2med hydrogen pipeline project, recently approved by the European Commission. A single branch of this network, the BarMar segment running from Barcelona to Marseille, spans 455 kilometres and will require more than 50,000 individual welds. Each weld is expected to consume 16 kWh of electricity.
If powered by diesel generators, these welds alone would result in emissions totalling roughly 480,000 tonnes of CO₂. However, by switching to hydrogen-powered welding with the Coolergizer, these emissions can be eliminated entirely, replaced by nothing more than water vapour.
Efficiency and Scale
According to COOLERGY’s estimates, welding one kilometre of hydrogen pipeline requires 1.3 MW of power—equivalent to around 63 kg of green hydrogen. A single Coolergizer unit can support five welding machines simultaneously. To achieve a pipeline laying speed of at least one kilometre per hour, between 17 and 20 Coolergizer units would need to operate in parallel.
This scalability makes the solution not just clean, but also practical for large-scale infrastructure projects.
Financial and Regulatory Incentives
In addition to the environmental advantages, companies adopting green welding solutions stand to benefit financially. By cutting CO₂ emissions, businesses can apply for carbon credits, which may be monetised under the European Union’s Carbon Border Adjustment Mechanism (CBAM) and other emissions trading frameworks. This adds a compelling economic incentive to the shift towards clean energy.
A New Standard for Sustainable Welding
As global infrastructure development accelerates, the need for sustainable practices in industrial operations has never been more urgent. COOLERGY’s Coolergizer not only offers a cleaner, mobile energy solution—it represents a broader shift towards greener construction technologies. With regulatory support and real-world applications already underway, green welding could soon become the industry standard.