ISENTIAL: Inline sensing for safer, more efficient electrolysers
Partners
TNO, TU Delft, Nel, Shell
Green hydrogen production depends on reliable, efficient and safe water electrolysis. In ISENTIAL, TNO leads a public–private partnership that develops and integrates fiber optic sensor systems for real time, in line monitoring of PEM and alkaline electrolysers. By embedding sensors directly into the electrolyser cell and stack, the project unlocks insights into internal operating conditions that are currently difficult or impossible to measure.
‘ISENTIAL shows how inline sensing can fundamentally improve our understanding of electrolyser operation. By bringing measurement inside the system, we enable safer operation and faster progress towards robust, large‑scale green hydrogen production.’
Seeing inside the electrolyser
Electrolysers operate under demanding electrochemical and thermal conditions. Local temperature gradients and unintended hydrogen crossover can reduce efficiency, accelerate degradation and pose safety risks. Until now, these effects have largely remained ‘out of reach’ for direct measurement.
ISENTIAL aims to address this challenge by integrating a multiparameter fiber optic sensor system inside the electrolyser itself. The sensors enable continuous, inline monitoring of parameters such as temperature distribution and hydrogen presence, providing a detailed view of what happens inside operating PEM (Proton Exchange Membrane) and ALK (alkaline) systems in real time.
From insight to impact
By making internal processes measurable, ISENTIAL supports better operation, design and control of electrolysers. The project focuses on:
- Early detection of hydrogen (H₂) crossover to improve safety
- Detailed temperature mapping to understand degradation mechanisms
- Enabling higher efficiency and longer operational lifetime of electrolysers
At the same time, ISENTIAL advances fiber optic sensing technologies towards higher technology readiness levels, bringing inline monitoring closer to industrial application.
Project facts
- Project type: public–Private Partnership (HTSM Smart Industry)
- Focus: inline, real time fiber optic sensing in PEM and ALK electrolysers
- Technology readiness: TRL 5–6 (basic parameters), TRL 3 (hydrogen sensing)
Public–private partnership
ISENTIAL is a Public–Private Partnership within the HTSM Smart Industry roadmap. The consortium brings together system developers, operators and research organisations, each contributing complementary expertise:
Develops the multiparameter fiber optic sensor system, leads sensor integration, testing and data analysis, and coordinates the overall project.
Develops and optimises metal hydride based coating materials for optical hydrogen sensing and performs fundamental research on hydrogen crossover detection.
Provides PEM and alkaline electrolyser cells and stacks and supports sensor integration and validation in industrially relevant configurations.
Defines use cases and sensor requirements from an operator and system perspective and contributes to interpretation of data for large scale hydrogen applications.
TNO’s added value
TNO combines in depth expertise in fiber optic sensing with extensive knowledge of hydrogen and electrolysis systems. This unique position enables TNO to bridge fundamental research and industrial application.
- Proven experience in developing fiber optic sensor technologies
- Deep understanding of both PEM and alkaline electrolysers
- Prior demonstrations of in cell fiber optic temperature sensing
- Access to advanced electrolyser test facilities, enabling rapid iteration between development and validation
Through ISENTIAL, TNO contributes to safer and more efficient green hydrogen production and strengthens the Dutch position in the hydrogen value chain and smart manufacturing technologies.
Discover more about ISENTIAL
ISENTIAL demonstrates how advanced sensing technologies can accelerate the transition from laboratory research to industrial hydrogen systems. Want to know more about inline monitoring, fiber optic sensors or hydrogen electrolysis? Contact TNO to explore collaboration opportunities.
Contact us
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Mark Courage
Functie:Director Smart Industry-
Standplaats:Delft - Stieltjesweg
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Email:Email Mark
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Stergios Georgantas
Functie:Project Manager-
Standplaats:Delft - Stieltjesweg
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Email:Email Stergios
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