Air Liquide is forging new paths with its ‘Trailblazer’ project in Oberhausen. The facility produces up to 2,900 tonnes of green hydrogen annually – enough to supply around 5,000 households with heat for an entire year. True to its name, ‘Trailblazer’ is paving the way for the future of hydrogen in Germany, marking a significant milestone in the development towards a sustainable energy economy. With this bold initiative, Air Liquide is not only advancing future-ready solutions for industry and mobility, but also laying the groundwork for a cleaner, more forward-looking future. Dräger was involved in shaping the safety concept from the very beginning and supplied the safety equipment.

Hydrogen (H₂) production has been part of Air Liquide’s expertise since the 1970s—yet with its ‘Trailblazer’ project, the company has raised the bar to a new standard. It is Germany’s largest production facility for renewable hydrogen that is connected to an existing hydrogen infrastructure. ‘With this, we’ve taken the lead,’ says Niklas Hülsenbeck, Plant Manager at Air Liquide. Spread across an area of approximately 40 by 60 metres, the site includes a stacks hall, a compressor hall, a control and instrumentation room, and a cooling tower. From here, hydrogen flows via the company’s dedicated pipeline network in the Ruhr region to customers in the chemical and heavy industry sectors. The Duisburg public transport operator also draws on this supply, using hydrogen from the ‘Trailblazer’ to power part of its bus fleet. 

Sustainable hydrogen production can only succeed if it meets the highest standards of safety. This is where Dräger comes in. As a specialist in gas detection systems, Dräger was involved from the outset in shaping the site’s safety concept and supplying the necessary technology. ‘My first visit to the OXEA site was in the summer of 2022,’ recalls David Simons. He is an Account Manager at Dräger and has worked with Air Liquide on several previous projects. One of the key challenges early on was defining the right gas detection technology. ‘To do this, we treated the construction site and the electrolyser as two distinct project areas, each requiring different solutions from our portfolio,’ says David Simons. The land designated for the ‘Trailblazer’ project was an empty plot—yet it was surrounded by existing chemical plants. This so-called brownfield land gave the project a unique complexity. Even before the first ground was broken, safety precautions had to be put in place to protect the construction site from potential hazards in the surrounding environment. 

‘We didn’t just bring Dräger on board as a technology partner, we specifically chose them for their expertise in construction site safety,’ explains Plant Manager Niklas Hülsenbeck. ‘The challenge on a major construction site like this is that multiple trades are working simultaneously. That significantly increases the risk of incidents.’ 

To address this, Dräger provided certified personnel, including safety observers and safety officers, specially trained to ensure protection across the site and for everyone working on it. ‘If all we do is deliver the gas detection devices, then we’re only doing half the job,’ says David Simons. That is why the on-site personnel received additional training from Dräger, to become qualified specialists and authorised experts in atmospheric clearance testing. For Niklas Hülsenbeck, the close working relationship with Dräger, along with the depth of safety consultancy they provided, were key advantages: ‘The flexibility of Dräger Rental & Safety Services was a decisive factor, and it’s something that really sets them apart in the industry.’ 

With the construction site secured, the real test lay ahead: maintaining uncompromising safety during ongoing production. The greatest risk? Hydrogen and oxygen present in the same environment—a volatile pairing that leaves no margin for error. Even at just 4 per cent concentration in the air, hydrogen becomes explosive, making any high-pressure storage a potential hazard. ‘These gases are stored under high pressure, which significantly increases the risk of leaks,’ explains Hülsenbeck, underscoring the need for strict safety measures. Bringing the facility into safe operation demanded engineering of the highest calibre, grounded in precision and expertise. One thing is certain: in gas detection, every metre matters and every second counts. To detect hazardous gases in time, transmitters must be positioned with strategic intent. The golden rule then becomes crystal clear: the higher, the safer—because as hydrogen (H₂) rises, it accumulates at the highest point in the room, which is precisely where the sensors need to be. 

When working with pressurised flammable gases, safety begins with precision. A commonly used benchmark, ‘the five-metre rule’, helps define the monitoring radius of a gas detection transmitter. To go beyond basic guidelines, Dräger’s engineers rely on computer-based gas dispersion modelling. Using a highly detailed digital twin of the facility—a virtual replica of the real-world installation—they simulate how gas would behave in the event of a leak. Circular detection zones are drawn around each sensor, ensuring that every corner of the plant is covered. ‘What good is a sensor,’ asks Sebastian Suski, Sales Engineer for fixed gas detection systems at Dräger and key account manager for Air Liquide in Oberhausen, ‘if the gas never reaches it?’ If the simulations reveal gaps, additional sensors are factored into the design. The goal is seamless—gap-free detection. Together with the client, the engineering team mapped out the detection strategy directly onto the site layout of the electrolyser, testing and refining it before implementation. 

Additionally, a standout safety feature of the Trailblazer plant is its SIL 2 certification. ‘Every safety component—from the sensor point to the alarm devices—had to meet the SIL 2 standard. That’s a rarity in this industry,’ says Suski. The sensors, however, are just one layer in a multi-tiered safety concept designed to guard against gas leaks through overlapping safety measures. 

Trailblazer’s safety concept is built around two core components: stationary gas detection systems and mobile devices. These highly sensitive sensors play a critical role in continuously monitoring hydrogen and oxygen levels throughout the facility. ‘We connect the sensors from our stationary Polytron 5200 and Polytron 5100 transmitters to our central control unit, the REGARD 7000,’ explains Sebastian Suski, Sales Engineer for stationary gas detection systems at Dräger. For personal protection, the mobile Dräger X-am gas detectors are easily clipped onto work jackets or workwear. These compact devices feature Dräger’s catalytic Ex sensor and are capable of detecting gases such as methane, propane, butane, and of course hydrogen, along with other explosive hydrocarbons. They also monitor oxygen levels in real time, ensuring that the breathing air contains enough—without exceeding safe limits. This dual approach, combining stationary and mobile detection, is vital for ensuring reliable protection across all areas of the facility. It confirms that nitrogen used to purge the system does not displace too much oxygen within the building, while also helping to detect any possible oxygen leaks. 

By combining mobile and stationary gas detection systems, the Trailblazer facility achieves continuous, round-the-clock monitoring with rapid alert capabilities. In the event of an incident, the Dräger control centre automatically triggers predefined safety responses: roller doors open to allow fresh air in, roof hatches unlock, and fans activate, forming a finely tuned safety system designed to respond to every eventuality. Based on initial operational experience, Dräger’s engineers recommended enhancing the fixed sensors mounted on the 15-metre-high hall ceiling with a remote monitoring solution. ‘This reduces maintenance costs while increasing overall safety,’ says Niklas Hülsenbeck. 

For Niklas Hülsenbeck, close collaboration on site was just as vital as the strong partnership with Dräger’s engineering team in Lübeck. ‘The team consistently brought us creative, well-grounded suggestions for improvement and offered hands-on support throughout the project,’ he shares. David Simons reflects on the project with a personal sense of pride: ‘It’s been a privilege to contribute to such a pioneering initiative. Hydrogen will play a central role in the energy transition—and we’re committed to making sure that this transformation happens safely. Because safety doesn't happen by chance. It is the foundation on which the success of projects like this is built. 

Author: Bernd Seidel & Friends     Photos: Patrick Ohligschläger     Published: June 2025