Temperature control failures in the process of converting biogas to hydrogen can lead to dangerous incidents and serious financial losses. We found this out when working with a company specialising in the design and manufacture of energy systems, which was looking for a temperature measurement chain supplier. In this case study, we will look at how advanced measurement technologies helped an innovative biogas-based hydrogen production project. You will learn how process safety and efficiency were ensured with comprehensive solutions that comply with the highest safety standards. Read on to find out what challenges were overcome to create a breakthrough solution for temperature control in the production of green hydrogen from biogas by steam reforming!
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.
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:
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.
Our certified solution has revolutionised the operation of the e-flox biogas plant, offering the following benefits:
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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