Hydrogen Power-to-Power (P2P) System, 1 Nm³/h electrolyser to 5 kW fuel cell.

Introduction

The Hydrogen Power-to-Power (P2P) System is a compact, integrated platform that demonstrates the complete hydrogen energy loop inside a single engineered enclosure. Built for universities, research institutes and industrial R&D centres, it combines automated sequencing, SCADA-ready monitoring and a layered safety architecture so labs can run repeatable experiments, log meaningful data and demonstrate dispatchable power from stored hydrogen.

Core capabilities

• On-demand hydrogen generation using a PEM electrolyser (lab-scale throughput).
• Hydrogen conditioning (separation, drying, filtration) for clean downstream operation.
• Solid-state storage in metal hydride canisters with active thermal management.
• Electricity generation using a PEM fuel cell, delivering stable 230 VAC through an inverter stage.
• Transient stability via an integrated battery buffer (load changes, start-up support, ride-through).
• Automation and safety interlocks using industrial PLC logic, with SCADA-ready communications.

Why it is valuable in a laboratory

• Complete hydrogen loop in one platform: instead of testing disconnected components, evaluate production, conditioning, storage behaviour and conversion back to electrical power under one control system and one data model.
• Solid-state storage suits lab environments: metal hydride enables a safer, more controlled storage approach than purely free-gas cylinders, and supports meaningful studies of storage kinetics.
• Repeatability and research-grade data: controlled operating sequences, stable setpoint control, alarm/event history and continuous monitoring let experiments be repeated, compared and documented.

How the system works

1. PEM electrolysis produces hydrogen from electrical input power and DM/DI water.
2. Hydrogen is conditioned (separation, drying, filtration) before being sent to storage.
3. Hydrogen is stored inside metal hydride canisters, where it is absorbed into the storage material.
4. When power is requested, hydrogen is supplied from storage to a PEM fuel cell.
5. The fuel cell generates DC power, converted to stable 230 VAC by the inverter stage.
6. A battery buffer supports transient loads, stabilizes output and improves dynamic response.

Detailed subsystems

DI water handling and quality management

PEM electrolysis demands high-quality water to protect stack health. A dedicated water handling arrangement supports practical refilling and level monitoring, controlled feed and circulation, and stable electrolyser conditions during long production campaigns, reducing operator dependency.

Hydrogen generation module (PEM electrolyser)

Controlled through PLC sequencing rather than manual steps: start permissives and safety checks before enabling production, automatic ramping, oxygen management/vent routing, and hydrogen routed through conditioning before storage.

Hydrogen conditioning

• Gas-liquid separation to remove entrained moisture.
• Hydrogen drying to achieve low moisture content.
• Filtration to protect valves, regulators and fuel-cell components.
• Pressure and temperature sensing points for traceable operation.

Solid-state hydrogen storage (metal hydride)

Metal hydride charging and discharging depend strongly on temperature: absorption releases heat and desorption requires heat input. Active heating/cooling control stabilizes charging, ensures predictable hydrogen availability during discharge and enables storage characterization experiments (temperature vs. capacity vs. flow behaviour), turning the storage block into a controllable experimental module rather than a passive tank.

Power generation (PEM fuel cell) and AC output

Automated fuel-cell start-up/shutdown sequencing, stable DC generation with continuous monitoring, inverter conversion to 230 VAC and battery buffering for transients and ride-through allow the system to demonstrate real, dispatchable power from stored hydrogen.

Controls, HMI, SCADA integration and data logging

• Industrial PLC control with safety permissives and fault handling.
• Touchscreen HMI for status, trends, alarms and setpoints.
• Role-based access (operator / technician / admin).
• Alarm/event history and continuous monitoring for research traceability.
• SCADA-ready communications (Modbus TCP / OPC UA) for integration into facility monitoring.

Operating modes

• Standby: energized and ready, monitoring sensors and permissives while production and generation remain inhibited.
• Hydrogen production: after permissives validate safe conditions, the electrolyser ramps to setpoint and storage charging is managed under closed-loop supervision.
• Storage management: charge and discharge controlled with thermal management and monitored for safe limits; alarm and safe shutdown if thresholds are exceeded.
• Electricity generation: the fuel cell is sequenced and stabilized, hydrogen supply is controlled from storage and the inverter delivers stable 230 VAC, with the battery buffer supporting fast load changes.
• Emergency shutdown (ESD): on gas detection, a critical fault or emergency stop, the system isolates hydrogen, stops production/generation and enforces a safe lockout/reset philosophy.

Safety philosophy and ATEX-free ventilation approach

Hydrogen safety is implemented as layered protection:

• Detection: hydrogen sensors placed near credible release points.
• Interlocks and permissives: hydrogen operation only when key conditions are healthy.
• Isolation and shutdown logic: automatic safe stop on alarm.
• Ventilation and extraction: dilution and removal of any credible release.

The ventilation strategy makes the cabinet/hood behave as a continuously purged and extracted space during permitted hydrogen operation, by maintaining forced extraction, tying hydrogen permissives to ventilation health, and using gas detection to trigger automatic safe shutdown and enhanced exhaust response (site-dependent). This is the engineering intent behind an “ATEX-free zone” operating philosophy, subject to final validation and hazardous-area assessment by the customer or site authority.

Mechanical layout and external interfaces

Packaged as a compact lab cabinet/skid with clear service access and defined connection points. Typical external connections:

• Power input supply and power output supply.
• Hydrogen outlet connection.
• DM/DI water inlet (refill).
• Thermal water interface (cold inlet / hot outlet) for the storage thermal management loop.
• Ventilation/extraction connection provisions.
• Operator interface panel: touchscreen HMI, Start/Stop and Emergency pushbuttons.

Scope of supply (typical)

• Integrated cabinet/skid with hydrogen generation, conditioning, storage, fuel cell, inverter, buffer battery and controls.
• Safety devices: gas detection, E-stop, shutdown logic and interlocked permissives.
• Instrumentation package for pressure, temperature and flow monitoring as configured.
• Documentation package (manuals, drawings, controls description).
• Commissioning support and operator training (project dependent).

Options and upgrades

• Higher electrolyser capacity / higher hydrogen throughput.
• Increased storage capacity or alternate storage approach (project dependent).
• Expanded instrumentation (dew point measurement, additional flow meters, extra temperature points).
• Advanced data exports and experiment “recipe” management.
• Outdoor/containerized configuration (site dependent).
• Enhanced HVAC/hood integration depending on the lab’s exhaust infrastructure.