{"id":3550,"date":"2026-08-06T13:27:10","date_gmt":"2026-08-06T05:27:10","guid":{"rendered":"https:\/\/www.acrel-electric.de\/?p=3550"},"modified":"2026-08-06T13:27:11","modified_gmt":"2026-08-06T05:27:11","slug":"wie-richtet-man-eine-gruene-wasserstofftankstelle-zur-eigenerzeugung-und-zum-eigenverbrauch-ein-die-sekundaerloesung-von-acrel-deckt-alles-von-hochspannung-bis-gleichstrom-ab","status":"publish","type":"post","link":"https:\/\/www.acrel-electric.de\/en\/wie-richtet-man-eine-gruene-wasserstofftankstelle-zur-eigenerzeugung-und-zum-eigenverbrauch-ein-die-sekundaerloesung-von-acrel-deckt-alles-von-hochspannung-bis-gleichstrom-ab\/","title":{"rendered":"How do you set up a green hydrogen refueling station for self-production and self-consumption? Acrel's secondary solution covers everything from high voltage to direct current."},"content":{"rendered":"
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Within the framework of the "Dual Carbon" initiative, the combination of photovoltaics and alkaline water electrolysis for hydrogen production has become a key pathway for the integration of renewable energies and the profound decarbonization of industry. The intermittent nature of wind and solar energy generation, harmonics during rectification, the flammability and explosion hazard of hydrogen, and the risk of DC leakage represent the four major challenges in the electrical design of hydrogen production plants. <\/p>\n\n\n\n

Based on the established ALK process of alkaline water electrolysis, Acrel has developed a comprehensive secondary solution that includes 10 kV high voltage, 24-pulse rectification, 0.4 kV auxiliary equipment, DC safety monitoring, and energy management. This solution addresses the challenges of the entire electrical chain of photovoltaic systems for the on-site generation and consumption of green hydrogen from four key perspectives: protection, measurement, explosion protection, and load balancing.<\/p>\n\n\n\n

1. Architecture of a photovoltaic system <\/h2>\n\n\n\n

Hydrogen production system: Four main components work synergistically to produce green hydrogen.<\/p>\n\n\n

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The complete photovoltaic system for on-site electricity generation and on-site hydrogen consumption with grid backup consists of four core components:
10 kV high-voltage distribution system:<\/strong> A PV step-up transformer and two power sources from the public grid ensure continuous hydrogen production even in insufficient sunlight.<\/p>\n\n\n\n

24-pulse phase-shifting DC system:<\/strong> It uses two phase-shifting transformers to rectify the alternating current into the low-voltage, high-current direct current required for the electrolyzer. Reactive power compensation in the high- and low-voltage ranges suppresses harmonics and reduces DC ripple.<\/p>\n\n\n\n

Electrolytic hydrogen production system: The main production line includes electrolyzer, gas-liquid separation, hydrogen purification, compression and storage.
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0.4 kV low-voltage power distribution for auxiliary equipment:<\/strong> Unified power supply for auxiliary consumers such as refill pumps, cooling units, air compressors and reactive power compensation.<\/p>\n\n\n\n

Operating logic: Prioritizes hydrogen production using green solar power. The public electricity grid serves as a backup when needed. This effectively converts surplus wind and solar energy into hydrogen, overcomes the challenge of integrating and consuming renewable energies into the electricity grid, and enables CO2-free hydrogen production throughout the entire process.<\/p>\n\n\n\n

2. 10 kV high-voltage secondary protection: Special protection for rectifier transformers<\/h2>\n\n\n\n

In accordance with standard NB\/T10447-2020, a five-stage protection system was implemented for 24-pulse, double-phase rectifier transformers and the operation of dual photovoltaic power sources. Each of the two rectifier transformers is independently equipped with a complete protection system to prevent short circuits, winding faults, and harmonic overloads.<\/p>\n\n\n\n

Overview of core device configuration<\/strong><\/p>\n\n\n

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3. Secondary equipment for grid-connected photovoltaic systems: Compliance with requirements against backflow and islanding<\/h2>\n\n\n\n

For decentralized PV systems with a 10 kV operating voltage and on-site power generation (surplus electricity is not fed into the grid), grid connection reliability is a mandatory requirement for commissioning. The complete system configuration minimizes the two main risks to grid compliance: islanding and backfeeding.<\/p>\n\n\n\n

Overview of core device configuration<\/strong><\/p>\n\n\n

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4. 0.4 kV Low-voltage auxiliary equipment measurement and control: Special protection for hydrogen production pumps and compressors<\/h2>\n\n\n\n

The motors for alkali feed, cooling, and air compression in hydrogen production plants run around the clock. The humid environment and alkaline mist can easily lead to motor seizures, power losses, and phase imbalances. Therefore, the low-voltage secondary equipment is specifically designed for potentially explosive industrial conditions.<\/p>\n\n\n\n

Overview of core device configuration<\/strong><\/p>\n\n\n

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5. Three essential safety devices for a solid foundation for explosion-proof hydrogen production<\/h2>\n\n\n\n

1) DC isolation monitor AIM-D100-TH<\/strong><\/p>\n\n\n

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Electrolyzers operate with direct current at low voltage and high current. The electrolyte is conductive; alkali leaks and moisture can easily lead to ground faults, and even a tiny electrical spark can trigger a hydrogen explosion. The system continuously monitors the insulation of the 100\u20131000 V DC busbar and immediately triggers an alarm and shuts down the system in the event of an insulation fault. It is a mandatory safety device in hydrogen production plants.<\/p>\n\n\n\n

2) Complete range of AC and DC measuring instruments<\/strong><\/p>\n\n\n

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3) BM200\/BM100 Intrinsically safe isolation barrier<\/strong><\/p>\n\n\n

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The hydrogen production area is classified as a potentially explosive atmosphere; the 4\u201320 mA signals for temperature, pressure, and fill level on-site must be isolated to limit the energy. Isolated safety barriers prevent the ingress of hazardous energy into the explosion-proof area and simultaneously block strong electromagnetic interference from the rectifier system, thus ensuring stable and reliable PLC control signals.<\/p>\n\n\n\n

6. Energy management system of the Acrel-2000MG hydrogen production plant: The intelligent control center for the entire plant<\/h2>\n\n\n\n

Hardware devices provide protection and monitoring, while the energy management system handles the integrated optimization and control of generation, transmission, consumption and storage \u2013 together they form the digital core platform for photovoltaic power plants for the production of green hydrogen.<\/p>\n\n\n

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Core system advantages<\/strong><\/p>\n\n\n\n

Coordinated multi-source feed-in<\/strong>Integrates solar energy, grid power, electrolyzers and energy storage; operates at full capacity for hydrogen production when solar power generation is high; uses grid power as backup at night or during cloudy periods; and maximizes the use of renewable energy;<\/p>\n\n\n\n

Comprehensive data monitoring:<\/strong> Aggregates data from 10 kV high-voltage systems, 0.4 kV auxiliary systems, DC electrolysis circuits, ambient temperature and humidity, and the operation of hydrogen plants to generate reports on power generation, energy consumption in hydrogen production, and operation and maintenance;<\/p>\n\n\n\n

Tiered fault reporting:<\/strong> Pop-up warnings with audible and visual indications of anomalies such as overcurrent, insulation damage, arcing, islanding, and motor overload; triggers automatic circuit breaker tripping to minimize the risk of incident escalation;<\/p>\n\n\n\n

Cost reduction through peak shaving and load gap balancing:<\/strong> By using electricity pricing strategies to reduce peak loads \u2013 increasing hydrogen production during off-peak hours and reducing electricity consumption from the grid during peak hours \u2013 the system significantly reduces the plant's operating costs.<\/p>\n\n\n\n

Integration of remote maintenance and operation:<\/strong> It supports both local large screens and cloud-based remote access, thus meeting the visual management requirements of operators, grid operators and maintenance service providers.<\/p>\n\n\n\n

7. Solution overview: Suitable for PV-based alkaline hydrogen production projects of any size<\/h2>\n\n\n\n

Currently, ALK's alkaline electrolysis technology holds a market share of over 80%. This secondary plant solution covers everything from small, decentralized photovoltaic hydrogen production plants to large-scale green hydrogen production facilities with a capacity of 10,000 tons, integrating wind and solar energy. It addresses several key challenges facing the industry:<\/p>\n\n\n\n

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  • 24-pulse rectification with harmonic suppression and staggered reactive power compensation for high and low voltages to ensure compliance with power quality standards;<\/li>\n<\/ul>\n\n\n\n
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    • Triple safety protection \u2013 three-phase differential protection on all sides of the rectifier transformer, DC isolation and explosion-proof safety barriers \u2013 for use under hazardous hydrogen operating conditions;<\/li>\n<\/ul>\n\n\n\n
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      • Comprehensive solutions for protection against islanding and backflow in PV systems ensure compliance with grid connection requirements without penalty fees;<\/li>\n<\/ul>\n\n\n\n
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        • Complete AC\/DC energy measurement for precise calculation of the cost per kilowatt hour of green hydrogen;<\/li>\n<\/ul>\n\n\n\n
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          • Integrated energy management platform for optimizing the consumption of renewable energies and reducing costs while simultaneously increasing efficiency.<\/li>\n<\/ul>\n\n\n\n

            As new energy systems are developed, photovoltaic water electrolysis for hydrogen production is a key factor for long-term energy storage and the decarbonization of industry. A robust and reliable secondary power grid forms the basis for the safe, stable, and economical operation of green hydrogen production projects. Acrel offers a comprehensive, turnkey solution \u2013 from microprocessor-controlled protection devices, measuring instruments, and isolation barriers to energy management platforms \u2013 thus supporting the large-scale implementation of the green hydrogen industry.<\/p>","protected":false},"excerpt":{"rendered":"

            Im Rahmen der \u201eDual Carbon\u201c-Initiative hat sich die Kombination von Photovoltaik und alkalischer Wasserelektrolyse zur Wasserstofferzeugung zu einem zentralen Weg f\u00fcr die Integration erneuerbarer Energien und die tiefgreifende Dekarbonisierung der Industrie entwickelt. Die intermittierende Natur der Wind- und Solarenergieerzeugung, Oberschwingungen bei der Gleichrichtung, die Brennbarkeit und Explosionsgefahr von Wasserstoff sowie das Risiko von Gleichstromleckagen stellen […]<\/p>","protected":false},"author":2,"featured_media":3552,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[9,4],"tags":[],"class_list":["post-3550","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-asien","category-projekte"],"_links":{"self":[{"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/posts\/3550","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/comments?post=3550"}],"version-history":[{"count":1,"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/posts\/3550\/revisions"}],"predecessor-version":[{"id":3560,"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/posts\/3550\/revisions\/3560"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/media\/3552"}],"wp:attachment":[{"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/media?parent=3550"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/categories?post=3550"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.acrel-electric.de\/en\/wp-json\/wp\/v2\/tags?post=3550"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}