THE FUTURE IS PRODUCED HERE

The electrochemical disintegration of water is taking on a whole new significance as a result of the growing capacities for volatile, green energy generation. Because storable hydrogen can be produced with surplus electricity, this process is considered to be climate-neutral when using CO₂-free generated electricity, including nuclear energy.

The functional principle is the same for all types of electrolysers: direct current is fed into an electrolytic cell with aqueous electrolyte. Hydrogen and oxygen form at the electrodes. The two reactive gases are separated inside the cell by a membrane, an indispensable contribution to explosion protection. Further explosion protection measures differ depending on the type of electrolyser. With low-pressure electrolysers, potentially explosive areas are largely avoidable. On the other hand, the more effecient pressure electrolysis systems require more effort for explosion protection. They have an operating pressure of up to 100 bar. The area of 0.5 m around the electrolyser is therefore at least classified as Zone 2. For this Zone, R. STAHL supplies a wide portfolio of explosion-protected systems and equipment, from remote I/O systems to solutions for status monitoring and coolers to luminaires.

The compression of gases play a major role in hydrogen production. Hydrocarbons, for example, have to be compressed during steam reformation, as the process takes place under increased pressure. But hydrogen itself is often compressed after production, e.g. in electrolysers, before it is stored and transported. In liquefied form, it can be filled into cryogenic containers. Compressed hydrogen is also used for fuelling commercial vehicles and passenger cars.

Explosion protection must be ensured for both the compression of explosive hydrocarbons such as natural gas and also hydrogen. For this, R. STAHL provides comprehensive expertise, not only from countless projects in the oil and gas industry, but also as a system partner for explosion protection. R. STAHL provided support for the Spanish high-pressure expert Hiperbaric, who developed a new type of hydrogen compression technology. In addition to providing support, R. STAHL also supplied ATEX control panels for Zone 1 and an HMI control panel for Zone 2. The safety of the high-pressure hydrogen technology, which can achieve up to 900 bar, is additionally ensured with the help of a ventilation system and various measuring instruments for detecting leaks. 

As of today, the most widespread process for producing hydrogen is steam reforming that uses natural gas mostly or biogas or light petrol. The starting material reacts with water under high pressure and at high temperatures to form synthesis gas, a mixture of hydrogen and carbon monoxide. The latter can be further converted with water vapour to carbon dioxide and hydrogen. Solid biomass is also a possible starting material. However, supercritical water and a special catalyst are then required.

Hydrogen can also be produced with the help of a methanol reformer. In it, a superheated methanol-water vapour mixture reacts under pressure to form carbon dioxide and water.  If a tube reactor is used for this purpose, the hydrogen is separated in another apparatus via a membrane. In a membrane reactor, on the other hand, the hydrogen-permeable membrane is located directly on the reactor wall. Methanol reformers are considered a possible component of a hydrogen drive passenger car.

It goes without saying that these processes - like any process that involves highly explosive, combustible gases pose highest demands on explosion protection. Use the knowledge and the comprehensive equipment portfolio of the explosion protection expert R. STAHL to ensure maximum safety.

The production of hydrogen succeeds with high efficiency if high-quality control panels are used for main and secondary processes and the plant operators are supported with reliable operating and monitoring systems. Both for electrolyser as well as pumps, compressors and valves, explosion-protected control and distribution panels that are planned and manufactured with great care is ideally suited. The remote I/O system IS1+, which is suitable for Zone 1 and Zone 2, is at the centre. It can be used in control cabinets for PLCs as well as in safety systems and basic protection control systems. These are complemented by a wide range of Ex-protected HMIs, including operator stations and panel mount devices for every application.
For the analysis of the gases, R. STAHL supports you together with a partner with suitable process analysis coolers. In addition to product quality, process quality is also very important. With the aforementioned remote I/O system and vibration monitoring, you can continuously supervise your plant. This allows you to implement predictive maintenance and minimise unplanned downtime.