Process Industry Undergoing Electrification: New Challenges in Functional Safety

The process industry is transitioning from traditional fuel-fired equipment to electrically powered alternatives, particularly in syngas and hydrogen production, where electrified steam methane reforming (e-SMR) offers a cleaner, more energy-efficient solution. This shift reduces CO2 emissions but introduces new safety challenges, particularly the need to de-energize high-power systems safely during emergencies. Historically, safety systems in SMR relied on mechanical devices like valves to manage hazards. In electrified systems, safely cutting off power is more complex, especially in high-current applications. Conventional approaches, such as using safety relays and contactors, create redundancy but lead to bulky, complex installations in large-scale systems. As part of the EReTech project, a 250 kW e-SMR was constructed, revealing similarities between the control systems of electric motors (inverters) and electrically heated reactors (thyristors). It was found that the Safe Torque Off (STO) function, commonly used in inverters, could provide a reliable and compact method for safely powering off thyristors. Implementing STO for e-SMR systems could significantly simplify installation while enhancing safety, making it a viable solution for large-scale electrification in the chemical industry.