~ Why the future of energy demands smarter automation ~
According to the International Energy Agency, the number of hydrogen projects announced globally surged by 50 per cent in 2023 alone. If all planned projects are realised, hydrogen production could reach 38 million tonnes per year by 2030, which is six times today’s levels. Here, Mark Richards, regional manager at automation control specialist Beckhoff UK, explains why producing, storing and using hydrogen safely and efficiently requires control solutions that are flexible and capable of operating in demanding environments.
As many industries continue to accelerate their path to decarbonisation, hydrogen is emerging as vital enabler in the transition to Net Zero. No longer a distant theoretical vision, the hydrogen economy is beginning to take shape. Its role in the global energy system is multifaceted.
Green hydrogen is produced by electrolysis using renewable energy. It offers a carbon-free energy carrier that can be used in transport, industry and power generation. Its potential to store renewable energy and to decarbonise sectors like steelmaking and chemicals makes it critical to the future energy mix.
However, the unique properties of hydrogen, including its small molecules, high flammability and requirements for high pressures and low temperatures create challenges. This means rethinking how we automate hydrogen facilities.
Integrated control systems capable of managing complex processes and ensuring safety at every stage are essential. Traditional automation architectures are based on separated and inflexible systems, making them ill-suited to this challenge. Instead, we need modular, PC-based automation platforms that can combine real-time control, monitoring, safety and connectivity in a single environment.
From electrolysis to storage
Electrolysis is the cornerstone of green hydrogen production, but while splitting water into its component elements may seem simple in principle, it requires finely tuned control over electrical input, temperature, pressure and chemical balances. Relatively small fluctuations can cause inefficiencies or damaged equipment. Electrolyser operators need to achieve high reliability and maximum efficiency.
This goal requires an automation platform that integrates control and measurement technology to enable precise management of the electrolysis process. Real-time data acquisition allows operators to optimise conditions continuously. In addition, these systems can incorporate predictive maintenance functions that analyse trends and predict failures before they happen, reducing costly downtime.
Hydrogen can be stored as a gas under high pressure, as a liquid at very low temperatures, or chemically in materials such as metal hydrides. Each storage method carries its own unique challenges. Metal hydride storage, for example, offers a compact and safe alternative to pressurised gas tanks, but if demands careful thermal management and pressure control.
GKN Hydrogen is a good example of a company employing this storage method. Their innovative systems use metal hydrides to safely store hydrogen at low pressures, offering long-term stability and high energy density. With up to 8.3 megawatt-hours of storage capacity in their HY2MEGA system, precise control is paramount.
Advanced automation systems continuously monitor temperature, pressure and system health, ensuring safe absorption and release of hydrogen. Real-time synchronisation of data across distributed sensors, combined with intuitive visualisation tools, gives operators the insight needed to manage complex storage systems.
Automation and hydrogen mobility
Hydrogen is set to transform transportation and mobility. Heavy-duty vehicles, trains and even aircraft are turning to hydrogen to cut carbon emissions. However, hydrogen fuelling presents challenges distinct from traditional petrol or diesel. Fuel must be dispensed at pressures up to 1,000 bar. Every step of the dispensing process must be monitored for safety, efficiency and reliability.
Automation must not only offer real-time control, but also seamless integration with Internet of Things (IoT) platforms. Operational data is captured and transmitted securely to cloud-based systems, enabling remote monitoring and optimisation of maintenance schedules.
A good example of what this looks like in practice is provided by Nel Hydrogen, a leading developer of hydrogen fuelling stations. Their stations are capable of serving dozens of vehicles daily and rely on fast, reliable control systems to manage the entire fuelling process — from monitoring tank pressure and temperature to detecting leaks and ensuring safe refuelling.
Real-time data from sensors is analysed instantly to control fuelling precisely, while simultaneously being transmitted to remote monitoring platforms. This approach ensure safety and efficiency of individual stations as well as providing fleet-wide insights that support wider system optimisation and predictive maintenance.
Open, scalable platforms are key to these developments. An open architecture facilitates seamless communication between diverse sensors, actuators and cloud services, regardless of manufacturer. It also ensures future-proofing, allowing operators to upgrade or expand their systems easily as technology requirements evolve.
Resilience and safety
Safety is paramount at every stage of the hydrogen value chain. Explosion risks must be mitigated not only in high-risk zones but throughout entire facilities. Automation platforms must therefore offer integrated functional safety, with the ability to process safety-relevant signals alongside regular process data.
In hazardous areas, equipment must be certified for explosion protection. Intrinsically safe input and output modules that are capable of operating directly within explosion zones, can dramatically simplify system design and reduce installation costs. They also allow for more flexible system layouts, essential for sprawling hydrogen production plans or refuelling sites.
Ensuring resilience against system failures is also crucial. Redundancy in communication networks, controllers and data storage projects against downtime supports continuous operation. Whether monitoring hydrogen pipelines that stretch for kilometres or managing distributed storage units, a robust, fail-safe approach is vital.
The rapid rise in hydrogen projects shows that momentum is building at an unprecedented rate. Automation technology is keeping pace, evolving to deliver the flexibility, safety and intelligence this sector demands. By embedding smart control across the entire hydrogen value chain, the industry can fulfil the enormous potential forecast by the International Energy Agency, driving forward a cleaner, greener energy future.
You can read more about Beckhoff’s technology for the hydrogen industry, including some of the project discussed in this article, here.
