Automation Sustainable shipping with hydrogen fuel cells

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In the maritime industry, there are currently many developments aimed at making shipping globally sustainable. Phoenix Contact is also aligning itself with the vision of the All Electric Society and is adapting its product and service portfolio to meet future requirements.

Niklas Lecker, Global Industry Management Marine, Phoenix Contact Electronics GmbH, Bad Pyrmont

The International Maritime Organization (IMO) is a specialized agency of the UN that promotes the safety of ships and seafarers at sea as well as reducing and ideally preventing the environmental impacts of shipping. To achieve these goals, the IMO develops international conventions for ship operations and increasing environmental compatibility. Specifically, concerning the long-term temperature goal of the Paris Climate Agreement, the specialized agency has developed a strategy to reduce greenhouse gas emissions and has set the global goal of making shipping climate-neutral by the year 2050.

Transition to alternative fuels

In light of this, the maritime industry currently hosts numerous solution-oriented projects focused on new technologies and various optimization possibilities for ship operations. In addition to hydrodynamic improvements to ships, adjusted speeds, optimized routes, and the reduction of all on-board energy consumption through more efficient systems, the supplementary use of wind power for main propulsion is also explored. However, the switch from environmentally harmful fuels—such as heavy oil or diesel—to alternative fuels represents the most effective measure for reducing emissions. This is because fuel on board is not only needed for the ship's main propulsion but also covers the entire energy demand, such as electricity and heat. Aside from alternative propulsion solutions, a search for more sustainable energy supply on ships is also underway.

As a flexible onboard energy supply solution, the hydrogen fuel cell is emerging prominently. For its operation, hydrogen and oxygen are required, which must be continuously supplied. Through an electrochemical process in a galvanic cell, electrical power and water are produced. Known as cold combustion, this process has lower energy losses compared to traditional combustion engines, leading to high efficiency. When green hydrogen is used, the emission of pollutants is virtually zero. Additionally, unlike conventional combustion processes, the electrochemical process causes minimal wear and noise emissions, which significantly reduces the need for spare parts on long journeys.

Flexible placement on board

The combination of low noise emissions and the potential for a compact, modular, and scalable construction of hydrogen fuel cell systems allows for their flexible placement on board. This ensures efficient use of the limited space available on a ship. The high flexibility is also evident on both the input and output sides of the electrochemical process:

• On the input side, hydrogen can be generated from various energy sources—such as methanol or natural gas—using a device known as a reformer. This eliminates dependence on pure hydrogen.

• On the output side, the electricity generated can either charge a battery or directly supply various consumption systems. In larger ships, it is also possible for the fuel cell to function as a supportive unit of the main propulsion system or, in smaller ships, even serve as the main propulsion.

Hydrogen fuel cells thus offer significant added value for global shipping. To ensure the safe operation of the fuel cells, the internal processes must be reliably monitored and controlled. Specifically, this involves monitoring data on various pressures, concentrations, fill levels, and temperatures. Based on this data, the control of drives and inlet and outlet valves is conducted. Additionally, certain power supplies and communication paths between the different trades within the fuel cell must be overseen.

Free programming of automation solutions

For such tasks, the PLCnext Technology ecosystem is suitable, which stands for open and free programming of automation solutions. For robust use on ships, the portfolio includes, among other things, controls approved for maritime applications from the PLCnext Control product family, as well as modular I/O modules from the Axioline F (AXL F) series. This combination ensures reliable and efficient management of complex systems and processes on maritime vessels.

For applications with limited space, selected components from the I/O product family, Axioline Smart Elements (AXL SE) can be used. The AXL SE series is based on two module carriers with four or six slots, which can be equipped with various I/O modules as needed. This opens up high flexibility while optimally utilizing the available space. The various performance classes of the industrial controls running on the Linux operating system, in combination with the two modular I/O systems, allow for a hardware setup based on a modular principle. The Axioline family includes digital and analog input and output modules as well as various function, communication, and safety modules.

Diverse services in the area of Safety and Cyber Security

For processing both standard and critical signals—such as external emergency stop signals or gas detection data—as well as for potentially issuing error messages or executing emergency shutdowns, a safety controller and appropriate programming are required. The AXL F XT SPLC 1000 small safety controller is designed for such applications. This full-fledged safety-oriented PLC is connected on the left side to a standard PLCnext Control, thereby extending its capabilities to include safe applications up to SIL 3. This integration facilitates the management of safety-critical tasks within automated systems, enhancing overall system reliability and safety compliance.

As with the standard control, the programming of the safety controller is carried out in the software environment PLCnext Engineer. Developers can thus work in a familiar environment. If the user lacks expertise in safety programming, Phoenix Contact provides support. Based on the specifications provided, the company's certified safety specialists can undertake the safety programming as a service. This ensures that even those without deep programming knowledge can implement and maintain safety critical systems effectively.

A similar offering is available in the area of Cyber Security. Although the PLCnext Control series controllers already have security features and hardening measures implemented, and have been certified by TÜV Süd according to IEC 62443-4-2, the connection to ship control systems or networking with other systems requires appropriate security measures. Here, the experts at Phoenix Contact, also certified according to IEC 62443, assist users in developing security concepts, ensuring that applications are comprehensively protected. This assistance helps to address specific security challenges and ensures that the systems adhere to high standards of cyber security, safeguarding against potential cyber threats.

The product portfolio of the PLCnext Control, Axioline F, and Axioline SE series represents the answer to challenges in the areas of functional safety, cyber security, flexibility, and compactness. Together with the services offered, Phoenix Contact thus becomes the ideal partner for automating maritime fuel cell solutions.