Intelligent sector coupling in Bremerhaven, Germany A complete value-added chain for green hydrogen has been realized in the HY.City.Bremerhaven. Innovative automation technology ensures reliable sector coupling and a secure remote connection.

The production of green hydrogen is part of the regional hydrogen ecosystem of the HY.City.Bremerhaven. The project is considered a lighthouse when switching from fossil fuels to regenerative fuels. GP Joule, a system provider for integrated energy solutions, is the general contractor for the green hydrogen project of HY.City.Bremerhaven GmbH & Co. KG. As a part of this, GP Joule has realized a complete value-added chain for green hydrogen. It starts with electrolysis as a key technology and includes compression and storage in mobile tankers. The concept also includes a service station and suitable fuel cell buses for public transport. Only the wind turbine generator was already in place on the Grauwallring industrial estate. The generator is used as an energy supplier for the electrolyzer.

Solutions were examined that provide the right type of energy in the required quantity at the optimum location at the right time. With the HyRunner, GP Joule has developed a mobile storage system that enables intelligent hydrogen transport from the electrolysis site to the service station or to industrial customers. The hydrogen trailers are a central component of the process chain. The vehicles include comprehensive control and interface intelligence. It had to be ensured that the explosion protection risk assessment did not limit the entire automation concept to expensive Ex components. In addition, it also had to be possible to transfer the data generated to a cloud, store it, and use it in a variety of ways.

The hydrogen service station autonomously supplies the hydrogen-based public transport system in Bremerhaven. From the perspective of digitalization, the HyRunner had to fit seamlessly into the digital process chain. Furthermore, the technical equipment for the data logistics must ensure a high level of availability.

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Hydrogen production and tank infrastructure are part of the core concept of GP Joule. The locations are equipped with independent control technology, autonomously automated, and able to communicate with the higher-level cloud intelligence of GP Joule on both sides. For maximum availability, redundant controller hardware has been integrated, which is coordinated by the ASR (Applicative System Redundancy) smart software solution. In the face of the increasing risk of cyberattacks, comprehensive security solutions were also integrated. The use of MGUARD remote maintenance routers ensures secure communication within the hydrogen ecosystem. Hydrogen trailers play a central role as mobile storage and transport tanks. Explosion protection was integrated cost-effectively using one functional modular system that covers Ex and non-Ex areas.

This project is an impressive demonstration that solutions and technologies needed to realize an All Electric Society are already available.