With innovative automation technology to intelligent sector coupling

Hydrogen is a widely discussed topic—in media, online, and at events. In Bremerhaven, Germany, it’s driving climate-neutral mobility. At the Grauwallring industrial estate, HY.City.Bremerhaven GmbH & Co. KG uses a wind turbine to produce hydrogen on-site via electrolysis.

GP Joule, acting as general contractor, implemented the green hydrogen project as part of a regional ecosystem and a model for transitioning from fossil to renewable fuels. Meanwhile, Phoenix Contact’s automation ensures reliable sector coupling and secure remote access. Furthermore, experts on ZDF’s Wiso (summer 2024) believe Germany’s SME sector is well-positioned to lead the global hydrogen transition. Bremerhaven demonstrates this potential, with GP Joule establishing a complete green hydrogen value chain for HY.City.Bremerhaven—using an existing wind turbine at the Grauwallring industrial estate for electrolysis to public transport fueling.

Technical support for the entire value chain

A key challenge in hydrogen supply is delivering the right energy type, amount, place, and time. Therefore, GP Joule emphasizes the need to consider the entire value chain and logistics, not just individual steps. Using its hydrogen mobility expertise, the company developed the HyRunner in Bremerhaven—a mobile system for transporting hydrogen from electrolysis sites to fueling stations or industrial users.

“Each of the two electrolysis containers at the wind turbine base runs at 1 MW, producing up to 900 kg of hydrogen daily—enough to fill a tanker in six hours,” says Marian Hieke, Head of Engineering at GP Joule. The hydrogen, initially at 30 bar, is compressed to 380 bar via a buffer storage system and compressors.

Cost-effective automation kit for Ex and non-Ex areas

Hydrogen trailers are vital to the transport chain, featuring advanced control systems in durable stainless steel cabinets. However, since hydrogen use raises explosion protection (Ex) concerns, a modular system helps reduce costs by combining Ex and non-Ex components. In Bremerhaven, Phoenix Contact uses Ex I/O modules from the Axioline series only where needed—such as for valve control in the HyRunner—eliminating separate Ex barriers. Meanwhile, standard Axioline modules handle non-Ex zones without compromising functionality.

Secure data transmission to the cloud

The system generates large volumes of data, transmitted to the cloud via a TC Router 3002T-4G and secured by a TC Mguard RS4000. This enables the mobile storage unit to communicate independently and securely, ensuring efficient refueling aligned with electrolysis and storage. “We can monitor fill levels, control valves, and track the trailer via GPS,” says Marian Hieke. A PLCnext Control system also supports legally compliant hydrogen billing.

Though the HyRunner is built for autonomous hydrogen supply to Bremerhaven’s public transport, it integrates fully into the digital process chain. Specifically, PLCnext Control acts as the main controller at the electrolyzer site, collecting data from electrolysis to tank trailers and transmitting it wirelessly via a TC Mguard router and antenna to a central evaluation unit.

High availability through redundancy

High availability is critical for HySite, the system managing data logistics. This is ensured by two Quint4-PS power supplies with a Quint-Oring redundancy module, supported by five battery modules and a Quint4-UPS for uninterruptible power. This setup bridges outages or enables safe shutdowns, crucial due to hydrogen’s reactivity. Two control units form a high-availability redundancy pair using Phoenix Contact’s ASR concept. A ring-structured network connects all submodules, ensuring fault tolerance.

Further use of (waste) heat and oxygen

Producing renewable hydrogen from wind power marks the start of hydrogen-based mobility in Bremerhaven. Electrolysis also generates significant waste heat and oxygen, which the HY.City.Bremerhaven team plans to use efficiently. A local district heating network could utilize the 340 kW of waste heat, with nearby commercial and industrial consumers offering strong potential. Plans for oxygen reuse are also underway.

360-degree security against cyberattacks

Phoenix Contact supports secure networking and sector coupling with certified components and solutions. Its TÜV Süd-certified development process (IEC 62443-4-1) ensures high security standards, while its experts assist partners in designing secure systems per IEC 62443-3-3.

PLCnext Control, part of the open PLCnext Technology ecosystem, is IEC 62443-4-2 certified and enables secure automation in the All Electric Society. With its 360-degree security approach—covering components, solutions, and services—Phoenix Contact is a trusted security partner.

Learn more about green hydrogen.