According to the International Energy Agency, the number of hydrogen projects announced globally surged by 50 per cent in 2023 alone. If all planned projects are realised, hydrogen production could reach 38 million tonnes per year by 2030, which is six times today’s levels. As many industries continue to accelerate their path to decarbonisation, hydrogen is emerging as vital enabler in the transition to Net Zero. No longer a distant theoretical vision, the hydrogen economy is beginning to take shape. Its role in the global energy system is multifaceted. Green hydrogen is produced by electrolysis using renewable energy. It offers a carbon-free energy carrier that can be used in transport, industry and power generation. Its potential to store renewable energy and to decarbonise sectors like steelmaking and chemicals makes it critical to the future energy mix. However, the unique properties of hydrogen, including its small molecules, high flammability and requirements for high pressures and low temperatures create challenges. This means rethinking how we automate hydrogen facilities. Integrated control systems capable of managing complex processes and ensuring safety at every stage are essential. Traditional automation architectures are based on separated and inflexible systems, making them ill-suited to this challenge. Instead, we need modular, PC-based automation platforms that can combine real-time control, monitoring, safety and connectivity in a single environment. From electrolysis to storage Electrolysis is the cornerstone of green hydrogen production, but while splitting water into its component elements may seem simple in principle, it requires finely tuned control over electrical input, temperature, pressure and chemical balances. Relatively small fluctuations can cause inefficiencies or damaged equipment. Electrolyser operators need to achieve high reliability and maximum efficiency. This goal requires an automation platform that integrates control and measurement technology to enable precise management of the electrolysis process. Real-time data acquisition allows operators to optimise conditions continuously. In addition, these systems can incorporate predictive maintenance functions that analyse trends and predict failures before they happen, reducing costly downtime. Hydrogen can be stored as a gas under high pressure, as a liquid at very low temperatures, or chemically in materials such as metal hydrides. Each storage method carries its own unique challenges. Metal hydride storage, for example, offers a compact and safe alternative to pressurised gas tanks, but if demands careful thermal management and pressure control. GKN Hydrogen is a good example of a company employing this storage method. Its systems use metal hydrides to safely store hydrogen at low pressures, offering long-term stability and high energy density. With up to 8.3 megawatt-hours of storage capacity in their HY2MEGA system, precise control is paramount. Advanced automation systems continuously monitor temperature, pressure and system health, ensuring safe absorption and release of hydrogen. Realtime synchronisation of data across distributed sensors, combined with intuitive visualisation tools, gives 30 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk Why the future of energy demands smarter automation As hydrogen takes centre stage in the transition to net zero, it’s also bringing fresh engineering challenges - many of which will sound familiar to fluid power specialists. Controlling high pressures safely, managing energy efficiently, and ensuring system integrity under demanding conditions are cornerstones of both hydraulic and hydrogen technologies. The rise of hydrogen infrastructure is, in many ways, the next frontier for the kinds of control and safety systems hydraulic and pneumatic engineers have long mastered. Mark Richards, regional manager at automation control specialist Beckhoff UK, explains why producing, storing and using hydrogen safely and efficiently requires control solutions that are flexible and capable of operating in demanding environments. KNOWLEDGE BASE
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