Why is the production of hydrogen from biogas a safety-critical process?

The production of green hydrogen is one of the key pillars of the energy transition to reduce greenhouse gas emissions and build a more sustainable future. In this context, biogas stands out as a unique raw material - renewable, CO₂-neutral and even enabling a negative carbon balance.

Our client, the German company e-flox GmbH, specialises in the design and manufacture of advanced energy systems and FLOX® technologies that efficiently use biogas to produce hydrogen. Their systems and burners are used for the low-emission combustion of residual gases from biogas treatment, process gases, landfill gas and many others. One of the unique features of the e-flox technology is the efficient dissipation of heat. A containerised system built by the customer is currently producing 100 kg of hydrogen per day. The unique steam reforming method it uses achieves 60% efficiency, while traditional electrolysis is only 20%. However, this impressive achievement comes with unique safety requirements.

Temperature measurement in biogas systems is a key element that directly affects the safety and stability of the processes. Why is it so important? Biogas plants often operate in explosive atmospheres (ATEX), where even the slightest deviation from the standard can lead to serious consequences. Stable temperature maintenance in the steam reforming process, a key stage in hydrogen production, is therefore an absolute priority.

How to ensure safe temperature measurement in biogas systems? The customer's challenge

As we mentioned, the client approached us with a need for safe temperature measurement in their container plant for H2 production.

The main aspects of the challenge included:

• Safety certification requirements: All measurement solutions had to be EX and SIL certified to operate safely in explosive atmospheres.
• Complexity of system integration: The measurement system had to be naturally integrated within the container plant.
• Operational efficiency: Temperature monitoring had to support the target efficiency without compromising safety standards.

How did certified thermocouples and temperature limiters ensure the safety of the biogas plant? Our solution

To meet the customer's requirements, we designed and delivered a comprehensive measurement solution that ensured both the highest safety standards and precision in the hydrogen production process.

We proposed EX/SIL-certified thermocouples, precisely adapted to the various measuring points in the steam reforming process. Thanks to these temperature sensors, it was possible to monitor the temperature at critical points, guaranteeing the stability and reliability of the entire process.

Measuring transducers, characterised by high reliability and accuracy, were also an important component of the system. They ensured not only precise readings, but also efficient data transmission, which was crucial in terms of integration into the entire container installation.

For added safety, we also supplied temperature limiters, which acted as an additional safety feature under varying operating conditions. They automatically stopped the process if set limits were exceeded, protecting both equipment and people.

The integrated measurement system was seamlessly implemented in the container plant, meeting all the requirements of EX and SIL standards. This provided the customer with a solution that not only met the highest safety standards, but also significantly simplified process management. This comprehensive approach allowed the entire installation to run smoothly, while minimising the risk of failure.

Benefits of a fully certified measurement chain

Our certified solution has revolutionised the operation of the e-flox biogas plant, offering the following benefits:

• Simplified process management: One integrated metering system reduced operational complexity.
• Meeting safety standards: Certified EX and SIL equipment increased protection in explosive atmospheres.
• Future-ready: The plant has gained a competitive edge in the growing hydrogen industry.

About the author

My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.

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