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Customer application

Cornerstone of the Energy Transition

Automation for Modular Hydrogen Generation
Hydrogen will play an important role as an energy storage system in the sustainable energy landscape of the future. The collaboration between WAGO and FEST demonstrates how production can already succeed with the help of modular concepts and the interplay of sophisticated automation technology.

FEST and WAGO:

  • High fail safety thanks to the WAGO Power Supply Pro 2

  • Quick commissioning via remote I/O modules

  • Cloud connection via MQTT

  • Ex-approved connection technology

Electric vehicles, heat or hot water generation: wind and sun now drive more electrons through electrical conductors – without detours, directly from the generator to the consumer. Indeed, it seems that the future of energy supply can’t manage without molecules. Energy must be stored. Some consumers are also thirsty for more energy in the tank than, for example, batteries currently offer. As the central ingredient in the energy cocktail of the future, the smallest molecule floats right through that drink: hydrogen. Produced with excess electricity generated from renewable sources, it forms both a potent energy storage system, and also an alternative energy supply for aviation, long-distance, heavy-duty and marine traffic.

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The electrolysis system in the container allows a standardized and modular design for system sizes with nominal loads up to 30 MW.

However, as convincing as the concepts appear on paper, there are still questions about the origin of green hydrogen. One solution lies right outside your door: electrolyzers display all of their benefits near wind farms or solar parks. Instead of throttling wind turbines or removing solar cells from the grid in the event of an oversupply, the green current that is not being drawn off can be used to split water into oxygen and hydrogen. FEST, headquartered in Goslar, offers these systems. The company, which belongs to the Schmidt Kranz Group, designs, develops, builds and installs individual hydrogen-electrolysis plants and supply systems for Power-to-X applications. These systems are not continuously monitored on site due to their size – a concept that only works if the engineering, system technology and automation work together perfectly.

Standardized Containers

“We work using largely standardized containers with a nominal output of two megawatts or more. This allows us to react flexibly to individual user situations,“ says Christian Perplies. He is the Senior Sales and Business Development Manager for Hydrogen Technology at FEST and has managed renewable energy systems for many years.

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Christian Perplies (Senior Sales and Business Development Manager for Hydrogen Technology, FEST GmbH)

The preliminary work for Perplies lies in business development, i.e., designing the projects and systems with customers. He analyzes the demand side and ensures that the correct mix of customers is available for the hydrogen in consumption scenarios. These can include hydrogen-electric vehicle fleets, reverse-current systems, or smaller consumers of basic chemicals. Appreciative buyers of green hydrogen, and thus long-term partners, can also be found in the metal processing and semiconductor industries.

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The WAGO I/O System Field ensures that the data from the sensor and actuator levels is routed seamlessly to the control level and on to the cloud.

On the other hand, the energy generation process must be consistent. After all, about 55 kilowatt hours of system power are required to produce one kilogram of hydrogen. It is advantageous in this case if renewable energy is available from different sources. “Optimally, the oversupplies overlap, that is, there are different, inexpensive power sources, which are not available for the electricity market, but can be fed into the electrolysis system,“ explains Perplies. For profitable operation, utilizing at least 50 percent of the electrolyzer is crucial to achieve an optimal mixture of utilization and electricity costs. Therefore, battery storage systems are also included in the planning as an additional element for smoothing an energy profile. The system can also use waste heat. “Therefore, we don’t limit ourselves but also propose using battery storage systems or heat applications in the planning phase to absorb peaks,“ he says.

Once these questions have been resolved, Perplies and his team deal with the design of the system itself. Operator tasks, installation areas, safety and logistics requirements, and approval procedures must be clarified and completed before the water can be continuously divided into its constituent parts. “If everything external is satisfied, we simply need to set up our modular systems and put them into operation via plug-and-play,” he says, adding, “our aspiration is for our systems to function autonomously.” This places high demands on the system, the automation technology used, and its suppliers.

Automation Supports Easy Commissioning

“There would be no acceptance for our systems without reliable, safe, autonomous, easy-to-maintain ‘off-the-shelf’ systems. Therefore, we’re happy to have a partner like WAGO, who meets these automation challenges and goes farther: the thorough preparation from assembly to commissioning helps us get extremely close to the plug-and-play ideal,” says Perplies.

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Christian Perplies and Nils Roth (Senior Area Sales Manager Industry, WAGO) in conversation with the WAGO I/O System Field

Let Power Communicate

Perplies also lists specific quality criteria: In addition to the materials and methods used in metal construction, the components – the PEM electrolysis stack, the high-pressure pumps, sensors and the system control and communication technology – must be intrinsically fail-safe. “For each component, we use well-known, established and ‘mature’ systems that have proven that they work in the past. Ideally, they have already been subjected to a certain evolution to reach the performance level we need.” For Perplies, quality is also reflected in the level of support. “My colleagues in electrical design have excellent communication with WAGO regarding the selection of components and securing the supply of these components.”

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The WAGO Power Supply Pro 2 is reliable, with overvoltage protection per category OVC II, and ensures safe operation even during overvoltage peaks.

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View of the system via remote I/O

Another argument in favor: WAGO supports their approach of using preconfigured components. This saves time during pre-assembly, which is reflected in reduced expenses, more cost-effective systems and higher reliability. Nils Roth, Senior Area Sales Manager for Industry at WAGO, is familiar with this request from many customers. “Our support for rapid commissioning on-site using our remote I/O modules is quite tangible. But our connection technology, our network components and the modular WAGO automation components that are approved for hazardous areas, are also especially suited for this project,” he continues. Using the standard IO-Link, the data is routed seamlessly from the sensor and actuator levels to the control level and on to the cloud. Users constantly receive the relevant system monitoring data via dashboards. “This allows us to monitor current flows, pressures and temperatures at certain critical points, and to show that the components are running smoothly, or to report problems as soon as they arise,” adds Roth.

WAGO I/O System Field

  • Customer-specific connection

  • Communication interface between the worlds of OT and IT

  • Open, flexible software

“This is exactly what we base our approach on as an integrator: we provide systems that allow the valuable PEM stack to run, to the greatest extent possible at its optimal system parameters, yet within strict limits,” says Perplies. He adds, “placing the WAGO components directly in the field is also worth gold because the control cabinet dimensions save space and the entire system appears visually to be very tidy, even though it is a complex system.” The automatic parameterization during commissioning and the self-monitoring functions are also advantageous. “When the system automatically checks whether the expected sensor is connected to the respective port, the time savings are significant,” says Perplies with satisfaction.

Ultimately, these comprehensive concepts will help advance the energy transition in Germany and Europe. There is enormous potential here: from component suppliers to system designers to electrical producers and consumers of green hydrogen. “These concepts are like those from a sci-fi story that work together to build a more sustainable economy,” says Roth.

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Christian Perplies and Nils Roth take a look at the technology in the control cabinet.

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