Efficient and safe operation with open automation solutions

Fuel cell systems are crucial for the All Electric Society, requiring efficient, reliable, and safe operation. What benefits do industrial solutions in connection technology, networking, and automation offer?

Though fuel cells have existed for over a century, they have recently gained attention for power generation. They convert the chemical energy stored in hydrogen and oxygen into electrical power, heat, and water without local pollution or noise. Additionally, fuel cells are more efficient than internal combustion engines, as they aren’t limited by Carnot efficiency.

When powered by green hydrogen, fuel cells are carbon-neutral. Some technologies use methanol or ammonia, reforming them to obtain hydrogen. If these fuels are made from green hydrogen and CO2 or nitrogen obtained directly fro the ambient air, the cycle remains carbon-neutral. The higher energy density of e-methane, e-methanol, and e-ammonia compared to hydrogen offers promising future applications in aviation and shipping.

Optimal adaptation to the relevant application requirements

Efficient and safe fuel cell operation requires optimal interaction of functional areas, including media processing, temperature and water management, internal power supply, safety, and automation. Standard IEC 62282-3-100 outlines these areas. Key to this interaction are data and energy connections, and connecting sensors (pressure, flow, temperature) and actuators (pumps, fans, valves). Leading manufacturers use Phoenix Contact’s robust connectors and data and power cables.

Sensors and actuators can be connected remotely to Axioline E I/O boxes or integrated into the control cabinet via Axioline F remote I/O family. The fuel cell stack is the system’s heart, and the automation system is its brain. Phoenix Contact’s PLCnext Technology platform allows optimal adaptation to I/O architecture and functional requirements. It supports IEC 61131, high-level language, and model-based development in Matlab/Simulink, reducing development time by using simulation-developed functions directly on the controller.

Functional safety and IT security over the entire lifecycle

Hydrogen as the primary energy carrier in fuel cells necessitates stringent safety measures. The IEC 62282-3-100 standard outlines basic safety requirements for stationary systems. Simple systems can use safety relays like PSRmodular or MACX MCR signal conditioners from Phoenix Contact. More complex applications use PLCnext Control safety controllers, enabling advanced monitoring of variables like pressure or temperature.

Customers can leverage Phoenix Contact’s safety experts’ extensive experience when choosing a safety concept. The team assists from the development phase, helping with risk analysis and defining the optimal safety concept. If needed, they also program the safety-related parts of the application software.

Stationary fuel cells, used as decentralized power generators like emergency or grid backup systems, require remote monitoring and maintenance for constant availability. IT security is crucial, especially for critical infrastructures. Phoenix Contact’s PLCnext Control family meets IEC 62443 security standards, and their FL mGuard security routers and mGuard Secure Cloud provide secure remote access solutions.

Fuel cells pave the way to the All Electric Society

Electrolysis to generate green hydrogen from renewable energy sources and fuel cell technology to convert the hydrogen back into electricity form the basis of the All Electric Society. They balance seasonal and regional fluctuations in solar and wind power. Fuel cells also couple sectors by converting stored hydrogen into electricity and heat for buildings like data centers or offices.

In transport, fuel cells can replace internal combustion engines where batteries are impractical due to low energy density and high mass, such as in heavy goods vehicles, rail, shipping, and aviation. When hydrogen’s energy density is insufficient, hydrogen-rich e-fuels like e-ammonia, e-methane, or e-methanol can be used.

Read more about fuel cells stack/module and power-to-X.