Green Hydrogen 4.0 How Sensors with IO-Link Contribute to the Energy Transition

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In the field of hydrogen production, IO-Link enables new dimensions of transparency, efficiency, and process safety. This is demonstrated by an innovative hydrogen project consisting of an electrolyzer, a hydrogen refueling station, and a trailer filling station located near Jumo's headquarters.

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 carrier produced solely with renewable energies such as wind or solar power, green hydrogen is considered one of the key hopes for decarbonizing critical sectors such as industry, heavy-duty transport, and energy supply.

Sustainably into the Future

A pioneering hydrogen project, consisting of an electrolyzer, a hydrogen filling station, and a trailer filling station, was recently implemented just 10.5 kilometers (6.52 miles) (as the crow flies) from the headquarters of Jumo GmbH & Co. KG. While local renewable energy facilities supply green electricity and the hydrogen filling station enables emission-free refueling, an electrolyzer takes on the crucial task of splitting water into hydrogen and oxygen.

As a specialist in innovative electrolyzer technologies, Fest GmbH from Goslar supplies the state-of-the-art PEM electrolyzers (PEM = polymer electrolyte membrane), which form the heart of hydrogen production. Fest's containerized 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.

Green Hydrogen is Produced from Renewable Electricity

The company not only contributes technological excellence "Made in Germany" but also extensive experience in planning, implementing, and supporting complex hydrogen projects. With their expertise, Fest GmbH ensures that renewable electricity is reliably and economically converted into green hydrogen—thereby laying the foundation for the overall project's success.

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Precise Measurement as the Basis for Efficient Production

During hydrogen production (electrolysis), water is split into hydrogen and oxygen using electricity—a highly sensitive process in which various process parameters must be precisely monitored. Even the smallest deviations can impact the efficiency of hydrogen production or lead to undesirable side reactions.

Precise temperature measurement, for example, ensures that the electrolyzer cells always operate within the optimal range and are protected from overheating and performance losses. Continuous monitoring of conductivity, in turn, is essential to ensure the quality of the electrolyte and to detect deposits or disturbances at an early stage. Error-free and stable measurement values are therefore indispensable for operating the PEM electrolyzer process safely, economically, and sustainably.

IO-Link: Smart Sensors for Maximum Process Safety

The advantages of IO-Link technology become evident even in the early project phases—long before the electrolyzer produces hydrogen for the first time. During the planning and commissioning of the system, the digital interface not only saves time but also reduces complexity: instead of complex wiring with separate cables for power and sensor data, a standardized cable with M12 connectors is used, transmitting both power and digital measurement values.

This reduces the wiring effort by up to 50 percent depending on the system. Commissioning also benefits: sensors can be centrally parameterized, configurations can be saved, and quickly transferred to other devices if needed. This saves time, enables seamless integration into the control environment, and increases flexibility for adjustments or expansions of the system.

Extensive Diagnostic Data in Real-Time

During operation, IO-Link demonstrates its full potential. The sensors not only provide precise measurement values but also extensive diagnostic data in real-time. For example, signs of wear or deviations can be detected early and addressed specifically—a crucial advantage for process safety and plant availability.

If a sensor replacement is necessary, the system automatically recognizes the new sensor and adopts the stored parameters, enabling a quick and error-free exchange. Remote diagnostics and maintenance are also facilitated by IO-Link: operators and service technicians can access the sensor information at any time without needing to be on-site.

Enormous Future Potential

The success story of IO-Link shows that the technology has long become a standard in industrial automation. Its future potential is enormous: with the increasing digitalization and networking of production facilities, IO-Link is becoming a key technology for Industry 4.0. In the field of hydrogen production, IO-Link enables new dimensions of transparency, efficiency, and process reliability—making projects like the electrolyzer in Hünfeld-Michelsrombach ready for the challenges of tomorrow.

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