In times of advancing climate change and the urgent need to replace fossil fuels, green hydrogen is increasingly coming into focus. As a versatile energy source that is produced exclusively from renewable energies such as wind or solar power, green hydrogen is considered one of the great hopes for the decarbonisation of key sectors such as industry, heavy goods transport and energy supply. A pioneering hydrogen project, consisting of an electrolyser, a hydrogen filling station, and a trailer filling station, was recently implemented just 10.5 km away from the headquarters of JUMO GmbH & Co. KG.
Electrolysers from FEST – ‘Made in Germany’
While local renewable energy plants supply green electricity and the hydrogen filling station enables emission-free refuelling, an electrolyser performs the crucial task of splitting water into hydrogen and oxygen.
As a specialist in innovative electrolysis technologies, Goslar-based FEST GmbH supplies state-of-the-art PEM electrolysers (PEM = polymer electrolyte membrane), which form the heart of hydrogen production. FEST's containerised systems are designed for maximum efficiency, safety and flexibility. Thanks to their modular design, they can be optimally adapted to the requirements of the location and enable scalable production – from pilot applications to large-scale hydrogen hubs. FEST not only contributes cutting-edge technology ‘Made in Germany’, but also extensive experience in the planning, implementation and support of complex hydrogen projects. With its expertise, FEST GmbH ensures that renewable electricity is reliably and economically converted into green hydrogen – thus laying the foundation for the success of the overall project.
Precise measurement is the key for efficient hydrogen production
During hydrogen production (electrolysis), water is broken down into hydrogen and oxygen using electricity – a highly sensitive process in which various process variables must be monitored precisely. Even the smallest deviations can impair the efficiency of hydrogen production or lead to undesirable side reactions. Precise temperature measurement, for example, ensures that the electrolysis cells always operate within the optimum operating range and are protected against overheating and power losses. Continuous monitoring of conductivity, in turn, is essential to ensure the quality of the electrolyte and to detect deposits or malfunctions at an early stage. Error-free and stable measurements are therefore indispensable for operating the PEM electrolysis process safely, economically and sustainably.
IO-Link: Smart sensors for maximum process reliability
The advantages of IO-Link technology are already apparent in the early project phases – long before the electrolyser produces hydrogen for the first time. During the planning and commissioning of the plant, the digital interface not only saves time but also reduces complexity: instead of complex wiring with separate cables for power and sensor data, a standardised cable with M12 connectors is used, which transmits both power and digital measured values. Depending on the plant, this reduces the wiring effort by up to 50%. Commissioning also benefits: sensors can be parameterised centrally, configurations can be saved and quickly transferred to other devices as required.
This saves time, enables smooth integration into the control environment and increases flexibility when adapting or expanding the plant.
IO-Link demonstrates its full potential during operation. Not only do the sensors provide precise measured values, they also deliver comprehensive diagnostic data in real time. This enables signs of wear or deviations to be detected early and addressed specifically, which is a significant advantage for process reliability and plant availability. When a sensor needs replacing, the system automatically recognises the new sensor and adopts the stored parameters, enabling quick and error-free replacement. IO-Link also facilitates remote diagnosis and maintenance, enabling operators and service technicians to access sensor information at any time, regardless of their location.
The success story of IO-Link shows that the technology has long since become the standard in industrial automation. Its future potential is enormous, particularly given the increasing digitalisation and networking of production facilities, where IO-Link is becoming a key technology for Industry 4.0. In hydrogen production, IO-Link opens up new dimensions of transparency, efficiency, and process reliability, making projects such as the Hünfeld-Michelsrombach electrolyser fit for tomorrow's challenges.
