Festo Automation Solutions for Green Hydrogen: Complete Portfolio from Electrolysis to Safety Control

Generating energy sustainably is one of the great challenges of our time — and green hydrogen is a building block of the solution. Hydrogen will play a key role in the future energy landscape and in the decarbonization of energy-intensive industries.

At the beginning of the hydrogen value chain is the production of hydrogen by means of electrolysis. In order to produce hydrogen with zero emissions, electrolysis using sustainable electricity is already used as an established technology. An automation concept that is perfectly matched to the electrolyzer is the key to its efficient, safe and long-term operation. Festo offers an extensive portfolio for this purpose, which covers the entire automation pyramid from the control level to the field level.

Control and Communication: CPX Remote I/O and VTUG Valve Terminals

Festo provides its own remote I/O modules (CPX-E, CPX-AP) and valve terminals (VTUG) for control and communication between the controller and process valves. All components are modular and freely configurable. This means that both input/output modules (digital, analog) and the fieldbus module can be adapted to the field devices and PLC.

This modular architecture enables electrolyzer control systems to be precisely matched to different scales and types of hydrogen production equipment, from laboratory-scale electrolyzers to industrial-scale hydrogen plants.

Process Valve Control: CMSH Positioner and VPPM Proportional Valves

Various types of process valves are used to control flow rates, gases and liquids, temperature, and other parameters in hydrogen production. In the classic case, the actuators — and thus indirectly the process valves — are controlled by means of a positioner. These use different methods to measure the position of the actuator or valve and control it to the position desired by the main controller. Festo offers the CMSH positioner for this purpose.

Another control device is the I/P transducer, a current/pressure transducer. This is used primarily in linear systems — but only when the position of the valve plays a subordinate role for safety-related consideration. Proportional valves such as the VPPM from Festo can take over the function of an I/P transducer. In doing so, they usually exceed the control quality and ease of use of the transducer, offering higher precision and faster response.

Safety First: Explosion-Proof Certification and SIL-Rated Products

Hydrogen is a colorless, volatile and non-toxic gas that is highly flammable and must be handled at high pressure. Numerous safety regulations must therefore be observed when setting up production and the necessary infrastructure. To get the green hydrogen produced to where it is to be used, it must be made transportable. This can be done, for example, by compressing it in a compressor station.

The safety of a plant is also important in the event of malfunctions or faults. Festo’s portfolio includes numerous products that are specially designed for use in potentially explosive atmospheres and are certified according to the IEC 61508 SIL standard, such as the VOFC and VOFD valves. The functional safety of electrolyzers is therefore essential to making industrial processes safe, efficient and environmentally friendly.

Custom Control Cabinet Solutions: Ready to Install

Festo also offers control cabinet solutions that meet the SIL standard. These protect components against environmental influences and foreign bodies. Regardless of whether pneumatic, electric or electro-pneumatic components are used, the end result is a fully designed control cabinet that centrally controls the actuators and sensors in the container. For applications in explosion-prone areas, the control cabinets can be planned, assembled and certified according to regional and international regulations.

Covering the Entire Hydrogen Value Chain

Festo’s green hydrogen automation solutions span the complete value chain:

• Electrolysis: CPX-E/CPX-AP remote I/O + VTUG valve terminals for device-level control and communication
• Process control: CMSH positioner and VPPM proportional valves for precise flow, pressure and temperature regulation
• Hydrogen compression and storage: Explosion-proof certified valves ensuring safety under high-pressure conditions
• Safety systems: VOFC/VOFD SIL-certified valves providing functional safety assurance
• Control cabinet integration: Customized, pre-certified complete control cabinet solutions

The full range of Festo hydrogen automation products is now available through Festo’s global sales network. Contact our technical engineers for project-specific selection and technical solution support.