Beckhoff controls operation of the first full-scale hydrogen station in the Baltic States
Utilitas' Väo energy complex in Tallinn has completed the first green hydrogen pilot plant in the Baltics, covering the entire value chain from production, purification, waste heat recovery, and distribution of hydrogen to consumption. This is an important step in Estonia's green transition that the Estonian energy system, implemented with modern technology from Beckhoff.
"The aim of the project was to build a working model station that demonstrates the potential of green hydrogen production and use, especially in the transport sector. It took almost two years to go from design to deployment, and the process involved close collaboration with many partners," says Risto Randla, one of the project partners and head of automation at Stargate Hydrogen.
The hydrogen plant, based on electrolysis technology, is capable of producing 400 kg of ultra-pure hydrogen per day, suitable for hydrogen cars, for example. In addition, the station's equipment will enable portable tanks to be filled and hydrogen to be transported to service stations and other end-users.
Stargate Hydrogen supplied the 1 MW Gateway 200 electrolyzer and Resato provided the compressor and refueling solution. This hydrogen, produced with green energy,is already finding its way into real transport solutions, in hydrogen cars ordered through the Bolt app – Toyota Mirai vehicles refuel at Alexela stations, which are supplied directly from the Utilitas plant.
The Beckhoff control solution was chosen as one of the key components of the project because of its high level of flexibility and due to Risto Randla's previous positive experiences with Beckhoff.
Beckhoff's role in the project
"Customers need the high quality technology we offer to be flexible, seamless, and backed up by expert technical support," says Roman Fjodorov, sales manager at Beckhoff Automation OÜ.
The TwinCAT programming environment provides/enables highly accurate process control and customization without hidden costs. The product range also includes Beckhoff I/O modules that meet zone 2 explosion protection requirements and the fast delivery time and competitive/attractive price are also factors in purchasing decisions. Beckhoff's PC-based control concept brought additional possibilities and flexibility to the project.
A control solution for the entire process
"The Beckhoff control system manages the entire electrolysis process, from splitting water to the production of high-purity hydrogen. The system continuously monitors temperature, pressure, and gas flow," Randla explains. "Based on this information, the controller automatically makes the necessary decisions to ensure smooth and safe operation."
At the heart of the system is the CX5200 Industrial PC, complemented by a wide range of EL series I/O modules, including ELX modules for ATEX environments, the TwinSAFE series of modules for safety, and the EP series of modules for outdoor use.
Users access the system via the CP29xx touchscreen HMI Panel, which makes system control intuitive and convenient.
Integration with further devices and subsystems is executed via standardized industry protocols – EtherCAT, PROFINET, and Modbus TCP/RTU. This enables real-time data exchange between devices from different manufacturers, which is critical for both reliability and data-driven optimization.
Software maintenance and upgrades are carried out according to a predefined schedule, usually when the station is not in operation, thus ensuring that the system is constantly reliable and always up-to-date.
Challenges and learning
"As this is the first project of its kind in the region, the team had to overcome a number of challenges. Introducing new technology and a new process required rapid learning, continuous adaptation, and a clear understanding of regulatory requirements," Randla says. He adds that Beckhoff's flexible system helped manage risk, as changes and additions could be made during development without major rebuilds.
The station is currently/now in the start-up phase and is running stably through the final optimization stages. At the end of the control period, the hydrogen production system will switch to autonomous operation. According to the user, the Beckhoff solution has proven to be a key factor in the success of the project, laying a reliable technical foundation for the next development steps for green hydrogen in Estonia and the Baltic region.