Hydrogen and synthetic fuel boom signals need for explosion protection
8 October 2025
Europe’s energy system has been changing shape for many years. While traditional refinery megaprojects have slowed, investment is accelerating into green hydrogen and synthetic fuels (e‑fuels). This new wave of energy projects gives opportunities for businesses helping to keep these evolving industries safe from explosion. Ex-tech Signalling is one of them as Mark Pemberton explains.
There are no refinery builds and few petrochemical sites being built in Europe right now. The market is mature and undergoing many closures and consolidations which has traditionally been our market for explosion proof sounders and flashing beacons.
The new wave of energy infrastructure being built in Europe features synthetic fuels or hydrogen for example, which have high volumes of flammable material in their production and supply chain.
From new electrolysis hubs to methanol and Fischer‑Tropsch (FT) facilities and hydrogen‑ready import terminals, the risk of explosion is potentially very high. Every part of these operations need to be designed, built and managed effectively to keep staff and the general public safe, which means most of the equipment throughout the supply chain needs to be explosion proof.
ATEX and IECEx Signalling for Europe’s Hydrogen and Synthetic Fuels Boom
At Ex‑Tech Signalling, our role is simple. We make visible and audible signalling products for hazardous areas. Whether a site handles hydrogen, methanol or syngas, our ATEX / IECEx certified sounders, beacons, manual call points and buttons help keep people and assets safe, today, and in a lower‑carbon future.
The Market Shift: From Hydrocarbons to Hydrogen & Synfuels
Europe’s latest tracker shows approximately 50,000 km of hydrogen‑capable pipeline proposals, 12 hydrogen‑derivative import projects, and more than 44 GW of hydrogen‑burning power capacity in development, most still pre‑FID (financial investment decision) but signalling a large opportunity and wave of growth.
For suppliers, EPCs, integrators and package builders, this means greenfield hydrogen and synfuel plants, and brownfield conversions (e.g. LNG terminals retrofitted for ammonia / LH₂) need fully engineered fire and gas (F&G) systems with Ex certified signalling devices installed from day one.
What is green hydrogen and synthetic fuel, and what are the explosion risks?
Used for transport, power and more, Green hydrogen is hydrogen produced by electrolysing water using renewable electricity, yielding H₂ and O₂ with near‑zero operational CO₂ emissions. It’s chemically identical to blue or grey hydrogen, so flammability and explosion risks are the same, but its climate impact is drastically lower when powered by renewables.
Hydrogen has a wide flammability range (~4–75% in air), with a very low ignition energy, fast diffusion and low‑visibility flame. That means it demands layered protection process such as leak prevention, early detection, safe ventilation, and clear alarm/evacuation signalling.
Synthetic fuels are man-made liquid fuels, such as e-fuels. They replicate the chemical properties of traditional petrol or diesel but are produced from non-fossil sources rather than from crude oil. They are also flammable like traditional petroleum-based fuels, and their production involves flammable substances like syngas, so the same principles apply regarding the potential release of flammable material in the supply chain.
That’s where Ex-tech Signalling explosion proof sounders and beacons come in, as they cannot be the source of an ignition when in use.
Where Ex‑Tech Signalling Fits in Synfuels and Hydrogen Plants
Typical applications we support across a plant include electrolysis halls, compression and storage areas, methanol synthesis units, and ammonia import and cracking facilities. For example:
- Explosion proof sounders: The SD150 (GRP) and SD125 (Stainless Steel) are ATEX / IECEx and SIL2 compliant options, engineered for loud, clear alerts in Zone 1 or 2 and harsh onshore and offshore environments.
- Explosion proof beacons and status lights: The BC150 (GRP) and BC125 (Stainless Steel) deliver high visibility warning with ATEX / IECEx certification and SIL2 compliant options for demanding duty.
- Explosion proof Call Points: The CP125 is an ATEX / IECEx flameproof Manual Call Point (MCP) with optional SIL2; designed for corrosive environments and compatible with PLC (Programmable Logic Controller)/ESD (Emergency Shutdown System)/DCS (Distributed Control System).
- Explosion proof Push Buttons: The PB135 (GRP) and the PB125 (Stainless Steel) are essential in hydrogen and synfuel plants allowing operators to manually trigger emergency shutdowns and integrate with fire and gas systems.
All Ex-Tech Signalling products are ATEX / IECEx certified and SIL2 rated.
Package builders, fire and gas detection and mitigation systems suppliers all require sounders, beacons and other devices when building equipment for synthetic fuel plants, methanol processing and hydrogen.
Greenfield and brownfield: Get Signalling right early
Greenfield sites benefit from new, modern design and fresh hazardous area classifications with audibility and visibility mapping to optimise device counts from the start.
Brownfield conversions on the other hand must tackle legacy cabling, mixed protection concepts and new muster philosophies. However, it is still possible to future-proof Brownfield Sites with easy replacement.
Benefit from:
- Consistent part numbering across generations – so when a replacement is needed, it’s possible to order the same part number without redesigning the system
- Backward compatibility – Ex-tech Signalling products are engineered to fit existing mounting patterns and cable entries, reducing downtime during swap-outs
- Lifecycle support – documentation and spares planning helps ensure a business is never left scrambling for obsolete components
This means brownfield sites can modernise signalling without ripping out infrastructure, and greenfield projects can plan for decades of easy maintenance. We are therefore with you to provide safety when handling hydrocarbons today, and in our carbon free future – whenever it comes.
Mini‑Checklist: Specifying Explosion Proof Signalling for Hydrogen & Synfuels
- Confirm zones and gas groups (IIC for H₂).
- Define alarm philosophy.
- Set SPL and candela targets.
- Choose Ex protection.
- Verify certificates.
- Plan power, supervision and addressing.
- Document proof tests and spares.
- Integrate with F&G logic
FAQs: Hydrogen, Synfuels & Hazardous‑Area Signalling
- Q) Is green hydrogen explosive?
- A) Yes. Hydrogen’s flammability / explosion characteristics don’t depend on how it’s produced. “Green” only describes renewable‑powered electrolysis.
- Q) What’s the difference between green, blue and grey hydrogen?
- A) Grey: from natural gas, CO₂ Blue: grey + carbon capture and storage. Green: electrolysis powered by renewables.
- Q) Why is signalling so important in hydrogen and methanol plants?
- A) Hydrogen is explosive and leaks can accumulate in confined spaces. Methanol is also both flammable and toxic and has the potential to leak in an operation. ATEX / IECEx‑certified signalling integrated with F&G systems provides the audible and visual layer that moves people to safety.
- Q) ATEX vs IECEx – do I need both?
- A) ATEX is mandatory in the EU/EEA. IECEx is internationally recognised and many operators specify dual certification.
- Q) How are hazardous zones defined for hydrogen?
- A) Areas where there are flammable liquids, vapours or gases are classified as Zone 0, 1 or 2 according to frequency, duration of explosive atmospheres and other factors. Hydrogen is considered a Group IIC gas because of its extremely low minimum ignition energy (MIE), which is the lowest energy needed to ignite it.
- Q) Which Ex‑Tech Signalling products are best for hydrogen/synfuel duty?
- A) SD150 sounders, BC150 or BC125 beacons and CP125 manual call points are all suitable for potentially explosive hydrogen and synthetic fuel applications. They are all ATEX / IECEx certified, highly robust and reliable with SIL2.
Get Started: Engage early and reduce risk. Contact us for support
About the Author
Mark Pemberton – With over three decades in the electrical and safety industries, Mark has driven commercial and operational growth across global markets with Petrel and Ex-tech Signalling, key brands of the Pioneer Safety Group. His expertise in explosion protection, hazardous area compliance, and safety-critical infrastructure makes him a trusted voice for safety in the hydrogen and synthetic fuel industries.
