Solvay and Sapio Launch 5 MW Green Hydrogen Hub in Rosignano

Solvay and Sapio Group have broke ground on the Hydrogen Valley Rosignano project at Solvay’s centuries-old chemical facility in Rosignano Marittimo, Tuscany. This isn’t just another build—it’s the dawn of a major bet on green hydrogen and renewable hydrogen. At its heart lies a 5 MW PEM electrolyzer that will run on a dedicated 10 MW photovoltaic solar farm. Together, they’re set to churn out around 756 tons of green hydrogen every year. That’s enough to swap out fossil-derived hydrogen in Solvay’s peroxide process, cutting CO₂ emissions by a verified 15% by mid-2026. With €16 million from the Tuscan Region under Italy’s National Recovery and Resilience Plan (PNRR), this is shaping up as one of Europe’s first true industrial hubs for renewable hydrogen.

Project Overview

Over the next ten years, Belgian chemicals heavyweight Solvay (est. 1863) and Italy’s gas pro Sapio (est. 1922) are pooling resources to build a fully integrated green hydrogen site. Sapio will handle design, construction and operation of the electrolyzer, while Solvay will weave the hydrogen straight into its peroxide line. By doing this, they’re taking the supply risk off the table and laying down a blueprint for industrial decarbonization that others can follow.

Historical Context

For decades, Rosignano Marittimo’s chemical complex ran on grey hydrogen made from natural gas, which left a hefty carbon footprint. Lately, Italy’s push—backed by the PNRR—has nudged big players towards renewable hydrogen and other green energy. Meanwhile, Sapio has been beefing up its hydrogen production chops, setting the stage for this flagship venture.

Technical Specifications

• PEM Electrolyzer (5 MW): Rapid response for solar-powered operation, splitting water into high-purity H₂ and O₂ with top-notch electrolysis efficiency.
• Photovoltaic Solar Farm (10 MW): A zero-emission power source dedicated to the electrolyzer. Any extra juice can be fed back to the grid or stored.
• Water Treatment & Storage: On-site feedwater purification plus modular H₂ compression to keep hydrogen delivery smooth.
• Annual Output: About 756 tons of green hydrogen—roughly 15% of the feedstock for Solvay’s peroxide production.
• Timeline: Groundbreaking on 18/11/2025, mechanical wrap-up by Q1 2026, full commissioning by mid-2026.

Strategic Funding & Partnership

This €40–50 million project is powered by €16 million from the Tuscan Region through PNRR funds, part of the EU’s NextGenerationEU push. The ten-year deal locks in a steady green hydrogen supply for Solvay while giving Sapio the scale it needs to grow. Shared governance, cost-sharing and strict performance metrics keep everyone rowing in the same direction.

Local & Regional Impact

• Cleaner air thanks to fewer CO₂ emissions and other pollutants.
• Creation of 50–70 construction jobs and about 20 permanent positions.
• Spurring on local supply chains—from solar panel manufacturers to engineering outfits.
• Putting Tuscany on the map as a go-to region for industrial green hydrogen hubs in Southern Europe.

Why It Matters

Green hydrogen is a game-changer for decarbonizing hard-to-abate sectors. By swapping out grey hydrogen, Rosignano tackles one of the chemical industry’s biggest emissions offenders. Plus, this project ticks boxes for Europe’s REPowerEU goals and Italy’s National Hydrogen Strategy, and it lays the groundwork for next-gen uses like fuel cell technology and clean ammonia production.

Potential Challenges

• Intermittency Management: Solar swings call for agile control systems—and maybe some battery buffering, too.
• Scale-up Risks: Hitting full capacity by mid-2026 will demand tight project management and fast-track permits.
• Storage & Distribution: On-site use keeps transport simple, but spreading hydrogen further afield means pipelines or tanker trucks.
• Regulatory & Financial Risks: Nailing PNRR milestones and grid-connection rules is crucial.

With construction underway, everyone’s eyes will be on Hydrogen Valley Rosignano to see how the electrolyzer performs, what capacity factors it hits, and how smoothly the integration goes. A smooth ramp-up could spark a wave of similar hydrogen production hubs across Southern Europe, supercharging industrial decarbonization and building out the continent’s renewable hydrogen infrastructure.