In Japan, a foul-smelling waste product is being transformed into a promising clean fuel for the future, driving cars and tractors.
Dozens of cows watch us warily, their breath forming cartoonish puffs in the crisp morning air.
It’s a brisk, snowy morning in Hokkaido, Japan’s northernmost island. The cold carries the unmistakable scent of cow manure—a pungent yet familiar byproduct of the region’s booming dairy industry. Covering 20% of Japan’s landmass, Hokkaido is the country’s second-largest island and home to over a million cows, supplying more than half of Japan’s milk and dairy products.
Today, we’re visiting a farm that seeks to turn this potent aroma into something valuable. Here, cattle manure is being converted into hydrogen.
When burned, hydrogen emits no carbon, making it an appealing alternative to fossil fuels. Many hope it will become a sustainable energy source, capable of heating homes and powering cars, trains, aircraft, and ships in the future.
#1However, the most common method of producing hydrogen today relies on methane
—a fossil fuel extracted from deep underground—resulting in significant carbon emissions. Another approach involves splitting water using electricity, but this process is costly and only truly low-carbon if powered by renewable energy sources.
The Shikaoi Hydrogen Farm, however, is taking a different approach—one that taps into a readily available waste product in Hokkaido. The island generates around 20 million tonnes of cow manure annually. If not properly managed, this waste can become an environmental hazard, releasing substantial methane emissions and contaminating water sources when it seeps into rivers and streams.
So, could this abundant byproduct instead be repurposed as a source of sustainable energy?
#2This initiative to generate hydrogen from livestock manure originated in Japan and remains unique to this region.
Maiko Abe from Air Water, one of several companies involved in the hydrogen farm project, explains, "This initiative to generate hydrogen from livestock manure originated in Japan and remains unique to this region."
We are visiting the facility in Shikaoi, a town in central Hokkaido, to film an upcoming episode of *BBC's TechXplore* focused on Japan. "Shikaoi accounts for 30% of Hokkaido’s cow waste and urine, giving it significant potential for renewable energy,"Abe adds.
Launched in 2015 by Japan’s Ministry of the Environment, the project aims to convert agricultural waste into hydrogen, creating a circular economy that benefits the local rural community. The process begins with collecting cow manure and urine from nearby dairy farms, which are then fed into an anaerobic digester at a central facility. There, bacteria break down the organic material, producing both biogas and liquid fertilizer. The biogas is then purified into methane, which serves as the raw material for hydrogen production.
#3Farm-Fueled Hydrogen: Powering Agriculture and Beyond
The plant currently has a hydrogen production capacity of 70 cubic meters (18,500 gallons), with an onsite fueling station capable of refueling around 28 hydrogen fuel cell vehicles per day, says Abe. While hydrogen can power fuel cell cars, this facility’s fueling station is specifically designed for agricultural vehicles such as tractors and forklift trucks. These machines are particularly challenging to electrify with batteries due to their large size and demanding workload.
By using hydrogen-powered vehicles around the farm, the project helps cut emissions that would otherwise be generated by conventional fuel sources. Additionally, cattle-derived hydrogen is stored in canisters and transported to power and heat other local facilities, including a sturgeon fish farm and the Obihiro Zoo.
#4Scaling Up Hydrogen: The Energy and Infrastructure Challenge
Hydrogen’s Challenges: Storage, Safety, and Infrastructure Demands
Despite its potential, hydrogen comes with its own set of challenges. As a gas, it must be stored in high-pressure tanks, but its low molecular weight makes it prone to leakage. It can also weaken metal storage containers over time, causing embrittlement, and due to its high flammability, strict safety measures are required during handling.
Another storage option is liquefying hydrogen by cooling it to cryogenic temperatures below –253°C (-423°F). However, this process is highly energy-intensive and demands extensive infrastructure, adding to the complexity of large-scale hydrogen deployment.
#5Hydrogen’s Energy Density Dilemma: More Power, More Space
Hydrogen vs. Fossil Fuels: Energy Density and Storage Challenges
Hydrogen contains nearly three times the energy of petrol (gasoline) by mass. However, due to its low molecular weight, it has a much lower energy density by volume—a litre of liquid hydrogen holds only a quarter of the energy found in petrol.
Simply put, as the lightest gas in the universe, hydrogen requires significantly more storage space per kilogram compared to fossil fuels like petrol, diesel, and natural gas. This makes large-scale production and storage highly energy-intensive and demands extensive infrastructure to accommodate its unique properties.
#6Overcoming the Cold: Hydrogen Production in Hokkaido’s Freezing Winters
Cold-Climate Challenges: Hydrogen Production in Hokkaido’s Harsh Winters
Beyond the usual hurdles, the hydrogen farm project in Hokkaido faces unique challenges due to northern Japan’s freezing climate. The region’s subzero winters require specialized technologies to ensure stable hydrogen production, preventing the small amounts of water vapor in methane from freezing.
Using agricultural waste as a methane source for hydrogen production is relatively uncommon, but the process itself is well established. It follows the same method used for natural gas-derived hydrogen—steam reforming. In this process, steam heated to 800°C (1,472°F) reacts with methane, generating hydrogen along with carbon monoxide and carbon dioxide (CO₂) as byproducts.
#7Sustainable Hydrogen: Progress, Potential, and Remaining Challenges
Balancing Sustainability and Challenges in Hydrogen Production
According to Abe, using cow manure as a methane source remains carbon neutral because the carbon it releases originated in the grass the cows consumed: "Since it was originally in the atmosphere, it is considered carbon neutral."
Additionally, the process prevents methane emissions that would otherwise escape from the manure—a crucial benefit, as methane is a potent greenhouse gas. The remaining slurry from the manure, after biogas extraction, is used as fertilizer for nearby fields, while formic acid, a byproduct of the process, could serve as a preservative for cattle feed, Abe explains.
Currently, the electricity required for hydrogen production and storage comes from the national grid. However, Abe notes that Hokkaido’s abundant wind, sea, and geothermal energy could eventually provide a greener alternative, further reducing carbon emissions.
Despite these advancements, significant challenges remain. High production costs, coupled with low demand for hydrogen, make scaling up operations economically difficult.
#8The High Price of Hydrogen: Costly Infrastructure for Fueling Stations
says Abe. "Since hydrogen vehicles are not yet widespread, we’re keeping our filling capacity low to manage initial investment. As adoption increases, we’ll expand supply."
Boosting Adoption: Making Hydrogen Affordable and Accessible
To encourage the use of hydrogen vehicles in the region, the plant subsidizes hydrogen prices, keeping them on par with petrol. Additionally, hydrogen refueling stations are being developed in major Hokkaido cities like Sapporo and Muroran, helping to expand infrastructure and support wider adoption.
#9Hype Meter
The process to make clean hydrogen fuel from cow manure in Shikaoi Hydrogen Farm is worth paying attention to, especially as it also reduces methane which would otherwise be released from the manure. With other countries exploring how to use other types of waste, from pig dung to coconut husks, to produce hydrogen using similar processes, it appears this could be a model adaptable to other local contexts.
With the scale still small, however, and costs of production high, it remains to be seen how widespread this industry can be. There are also other ways of producing fuel from cow waste, such as simply using the biogas produced from manure as a fuel itself without needing to convert it to hydrogen.
#10Japan’s Hydrogen Push: Leading the Way but Facing Cost Challenges
Japan is a global leader in hydrogen vehicle technology, having invested heavily in its development. However, for now, battery-powered electric vehicles (EVs) remain the more affordable option compared to hydrogen-powered alternatives.
#11Waste to Fuel: The Growing Potential of Hydrogen from Biomass
While cow manure alone is unlikely to meet Japan’s full hydrogen demand, it could still play a significant role. The Shikaoi project is demonstrating a circular economy model, aiming to show how costs could decrease as production scales up.
Globally, interest is rising in using waste materials to produce hydrogen. Researchers have explored pig dung, poultry waste, and even coconut husks as potential feedstocks. In Thailand, Toyota is experimenting with hydrogen derived from chicken waste to fuel its vehicles, further highlighting the potential of biomass-based hydrogen production.
#12Innovative Hydrogen: Turning Waste into a Low-Energy Fuel Source
Engineers at the University of Illinois Chicago (UIC) have recently developed a new method for producing hydrogen using manure, sugarcane waste, and corn husks. Their approach converts these materials into biochar, a carbon-rich substance that significantly reduces the electricity required to split water into hydrogen.
"We are the first group to show that you can produce hydrogen utilizing biomass at a fraction of a volt," says Meenesh Singh, a chemical engineer at UIC who led the project.
Meanwhile, in Fukuoka, a city in southern Japan, another unconventional waste product is being used to generate hydrogen—this time, the source isn’t livestock but humans.
#13Human Waste to Clean Energy: Fukuoka’s Hydrogen Innovation
For over a decade, Fukuoka’s sewage treatment plant has been producing hydrogen to power hydrogen-fueled vehicles. More recently, this clean fuel has been used to operate a fleet of zero-emission rubbish trucks, contributing to the city’s sustainability efforts.
According to Akira Miyaoka, hydrogen utilization manager for Fukuoka City, commercial trucks—not large factories—are the main source of CO₂ emissions in the city. "So we are working to reduce CO₂ emissions from commercial trucks," she explains, highlighting the city’s commitment to greener transport solutions.
#14From Waste to Energy: Fukuoka’s Sewage-Powered Hydrogen
Originally launched as a collaboration between Kyushu University and Fukuoka City, this hydrogen initiative has since expanded to include major companies like Toyota.
"Sewage is something that is steadily discharged every day in the daily lives of citizens," says Akira Miyaoka. "By making effective use of that sewage and extracting hydrogen as energy, we can achieve local production and local consumption of energy."
This approach not only provides a consistent and renewable hydrogen source but also supports sustainable urban energy solutions.
#15Turning Human Waste into Hydrogen: The Process Behind Fukuoka’s Innovation
Hydrogen production from human waste begins when household wastewater—from showers, dishwashers, and toilets—arrives at the treatment plant. As the water undergoes purification, the remaining sludge is retained and used as a biogas source, which is then converted into hydrogen.
"Sewage and biogas contain various impurities, so the process begins with removing those impurities, which I think is a little different from other hydrogen production processes," explains Akira Miyaoka.
This unique method ensures that wastewater is not only treated efficiently but also repurposed into a valuable energy source.
#16Japan’s First Hydrogen-Powered Service Fleet: Waste Fueling the Future
In 2024, Toyota partnered with Fukuoka City to launch Japan’s first hydrogen-powered service vehicle fleet, which includes ambulances, delivery vans, and bin trucks.
Officials at the sewage treatment plant report that the facility can generate 300kg (661lbs) of hydrogen in just 12 hours—enough to fuel 30 trucks.
Each hydrogen-powered rubbish truck operates six nights a week, silently collecting 1.7 tonnes (3,700lbs) of waste per trip—all while running emission-free on hydrogen produced from human waste.
#17Global Adoption of Sewage-to-Hydrogen Technology
Fukuoka’s sewage-to-hydrogen fueling station, in operation since 2015, has inspired similar initiatives worldwide.
Companies like Concord Blue have developed waste-to-energy plants in Germany, India, Japan, and the US, converting waste and biomass into hydrogen and bioenergy.
Meanwhile, in the UK, several water authorities are actively developing projects to extract hydrogen from sewage, signaling a growing global shift toward sustainable hydrogen production.
#18Sewage-Powered Vehicles: From Race Cars to Jet Fuel
In the UK, a prototype race car powered by sewage-derived hydrogen has been developed by the Warwick Manufacturing Group (WMG) in collaboration with Severn Trent Water. They are using microbes to generate hydrogen fuel from waste and expect the technology to become mainstream within five years, despite current challenges.
On a larger scale, aviation—responsible for 2% of global carbon emissions—could also benefit from waste-based fuels. UK researchers have successfully created jet fuel entirely from human sewage, offering a potential breakthrough for sustainable air travel.
However, while these technologies hold great promise, they have yet to be implemented at a significant scale.
#19Community-Driven Innovation: Hydrogen’s Role in Sustainable Transport
From rural farms to urban sewage plants, Japan’s hydrogen projects stand out for their community-centered approach.
While the adoption of hydrogen cars has slowed, the use of hydrogen-powered trucks is steadily rising. These larger, heavier industrial vehicles have a greater per-vehicle impact on greenhouse gas emissions, making their transition to clean energy a crucial step toward reducing carbon footprints.
