Details

Introduction
Turnkey PEM Electrolysis + Solid-State Hydrogen Storage + Fuel-Cell Power Generation (Laboratory Cabinet / Skid)

Hydrogen only becomes a practical energy carrier when you can generate it safely, store it responsibly, and convert it back into stable electricity whenever needed. The Hydrogen Power-to-Power (P2P) System is a compact, integrated platform that demonstrates the complete hydrogen energy loop inside a single engineered enclosure:

Electricity → Hydrogen (PEM Electrolysis) → Storage (Metal Hydride) → Electricity (PEM Fuel Cell + Inverter)

Designed for universities, research institutes, and industrial R&D centers, this system is built to behave like real industrial equipment—not a basic demo rig. 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.

System Overview
Core capabilities
• On-demand hydrogen generation using a PEM electrolyser (lab-scale throughput)
• Hydrogen conditioning (separation, drying, filtration philosophy) for clean downstream operation
• Solid-state hydrogen storage using metal hydride (MH) 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 (smooth load changes, start-up support, ride-through)
• Automation + safety interlocks using industrial PLC logic
• Monitoring & integration via standard industrial communications (SCADA-ready)

Why this system is valuable in a laboratory
1) Complete hydrogen loop in one platform
Instead of testing disconnected components, the P2P system enables full-cycle evaluation: hydrogen production, conditioning, storage behavior, and conversion back to usable electrical power—under one control system and one data model.

2) Solid-state storage is better suited for lab environments
Metal hydride storage is widely preferred in research environments because it enables a safer and more controlled storage approach compared to purely free-gas cylinders, while also enabling meaningful studies of storage kinetics.

3) Designed for repeatability and research-grade data
The system is built around controlled operating sequences, stable setpoint control, alarm/event history, and continuous monitoring so experiments can be repeated, compared, and documented.

How the system works (energy flow)
1. PEM electrolysis produces hydrogen from electrical input power and DM/DI water.
2. Hydrogen is conditioned (separation + drying + filtration philosophy) 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 which is converted to stable 230 VAC output through the inverter stage.
6. A battery buffer supports transient loads, stabilizes output, and improves dynamic response.

Detailed Subsystems
1) DI Water Handling & Quality Management
PEM electrolysis demands high-quality water to protect stack health and ensure consistent production. The system includes a dedicated water handling arrangement to support:
• practical refilling and level monitoring
• controlled feed and circulation behavior
• water-quality philosophy suitable for PEM operation
• stable electrolyser conditions during long production campaigns

This subsystem is engineered to reduce operator dependency and support long-duration, repeatable hydrogen generation tests.

2) Hydrogen Generation Module (PEM Electrolyser)
The PEM electrolyser is controlled through PLC sequencing rather than manual steps. Typical functional behavior includes:
• start permissives and safety checks before enabling production
• automatic ramping and controlled operation
• oxygen management/vent routing philosophy
• hydrogen routed through conditioning stages before storage

The result is stable hydrogen generation with structured alarms, interlocks, and repeatable run conditions.

3) Hydrogen Conditioning (Separation, Drying & Filtration)
Reliable fuel-cell operation requires clean, dry hydrogen. The conditioning philosophy typically includes:
• gas-liquid separation to remove any entrained moisture
• hydrogen drying to achieve low moisture content
• filtration to protect valves, regulators, and fuel-cell components
• pressure/temperature sensing points for traceable operation

This section is critical for long-term system reliability and consistent research results.

4) Solid-State Hydrogen Storage (Metal Hydride Module)
The system stores hydrogen in metal hydride canisters, enabling safe and controlled storage behavior and a stable supply to the fuel cell.

Active thermal management (key differentiator)
Metal hydride charging and discharging depend strongly on temperature:
• absorption releases heat
• desorption requires heat input

The system includes active thermal management (heating/cooling control) to:
• stabilize charging behavior
• ensure predictable hydrogen availability during discharge
• enable storage characterization experiments (temperature vs. capacity vs. flow behavior)
This turns the storage block into a controllable experimental module rather than a passive tank.

5) Power Generation (PEM Fuel Cell) + AC Output System
The fuel-cell module is integrated with power electronics to provide usable, stable AC output:
• automated fuel-cell startup/shutdown sequencing
• stable DC generation with continuous monitoring
• inverter conversion to 230 VAC
• battery buffering for transients and ride-through

This architecture allows the system to demonstrate real, dispatchable power from stored hydrogen and support laboratory loads in a controlled manner.

6) Controls, HMI, SCADA Integration & Data Logging
The P2P system is designed as a modern automated test platform:
• Industrial PLC control with safety permissives and fault handling
• Touchscreen HMI for status, trends, alarms, and setpoints
• Role-based accessAlarm/event history and continuous monitoring for research traceability
• SCADA-ready communications  (common industrial protocols) for integrationinto facility monitoring

Operating Modes
Standby mode
The system remains energized and ready, continuously monitoring sensors and permissives while hydrogen production and power generation remain inhibited until enabled conditions are met.

Hydrogen production mode (electrolysis)
After permissives validate safe conditions, the electrolyser ramps to setpoint, hydrogen is produced and routed through conditioning, and storage charging is managed under closed-loop supervision.

Storage management mode
Charging and discharge behavior are controlled with thermal management and monitored for safe limits. The system alarms and safely shuts down if conditions exceed defined thresholds.

Electricity generation mode (fuel cell)
The fuel cell is sequenced and stabilized, hydrogen supply is controlled from storage, and the inverter delivers stable 230 VAC output. The battery buffer supports fast load changes and smooth transitions.

Emergency shutdown (ESD)
In the event of a safety trigger (e.g., gas detection, critical fault, or emergency stop), the system isolates hydrogen, stops production/generation, and enforces a safe lockout/reset philosophy consistent with hydrogen safety engineering.

Safety Philosophy and Non-ATEX Ventilation Approach (Integrated)
Hydrogen safety is implemented as layered protection:
• detection (hydrogen sensors placed near credible release points)
• interlocks & permissives (hydrogen operation only when key conditions are healthy)
• isolation & shutdown logic (automatic safe stop on alarm)
• ventilation & extraction (dilution and removal of any credible release)

Ventilation basis for an “ATEX-free zone” cabinet/hood philosophy
The ventilation strategy is designed so that, during permitted hydrogen operation, the cabinet/hood behaves as a continuously purged and extracted space, reducing the likelihood of any flammable atmosphere forming inside the enclosure. Practically, this is achieved by:
• maintaining forced extraction during hydrogen operation
• tying hydrogen permissives to ventilation health
• using gas detection to trigger automatic safe shutdown and enhanced exhaust response (site-dependent)

This is the engineering intent behind maintaining an “ATEX-free zone” operational philosophy for the cabinet/hood environment, subject to final validation and hazardous-area assessment by the customer/site authority.

Mechanical Layout & External Interfaces
The system is packaged as a compact lab cabinet/skid with clear service access and defined connection points to simplify installation and commissioning.
Typical external connection points
• Power input supply
• Power output supply
• Hydrogen outlet connection
• DM/DI water inlet (refill)
• Thermal water interface connections (cold inlet / hot outlet) for the storage thermal management loop
• Ventilation/extraction connection provisions
• Operator interface panel: touchscreen HMI, Start/Stop, Emergency pushbutton

Technical Specifications

  

    
Parameter
    
Specification
  
  

    
System type
    
Turnkey Hydrogen Power-to-Power (electricity → H₂ → electricity) laboratory cabinet/skid
  
  

    
Hydrogen generation
    
PEM electrolyser (air-cooled), automated sequencing
  
  

    
Hydrogen generation rate
    
Up to 1.0 Nm³/h
  
  

    
Electrical input
    
230 VAC, 50/60 Hz (final protective device rating as per configuration)
  
  

    
Hydrogen conditioning
    
Separation + drying + filtration philosophy for clean downstream operation
  
  

    
Hydrogen storage type
    
Metal Hydride (MH) solid-state storage
  
  

    
Hydrogen storage capacity
    
Up to 5 kg H₂ (configuration dependent)
  
  

    
Storage thermal management
    
Active heating/cooling control to manage absorption/desorption behavior
  
  

    
Power generation
    
PEM fuel cell (air-cooled) integrated with inverter stage
  
  

    
Fuel cell power
    
 5 kW class
  
  

    
AC output
    
230 VAC via inverter, ~5 kW class output
  
  

    
Energy buffering
    
~5 kWh Li-ion battery buffer for transient handling / ride-through
  
  

    
Controls
    
Industrial PLC + touchscreen HMI, alarms, permissives, automated modes
  
  

    
SCADA / communications
    
Ethernet integration; SCADA-ready via common industrial protocols
  
  

    
Safety features
    
Gas detection, ESD logic, interlocks/lockouts, ventilation permissive philosophy
  
  

    
Cabinet format
    
Compact lab enclosure with defined service ports and operator interface
  


Typical Applications
• University hydrogen teaching labs and demonstration platforms
• Renewable-energy storage studies (power-to-gas / gas-to-power)
• Fuel-cell system integration and inverter behavior evaluation
• Metal hydride characterization (temperature-controlled charge/discharge experiments)
• Backup/dispatchable power demonstrations under varying load profiles
• Safety logic validation (cause-effect testing, detector response, shutdown strategy)

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/flow monitoring as configured
• Documentation package (manuals, drawings, controls description)
• Commissioning support and operator training (project dependent)

Options & 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 support depending on the lab’s exhaust infrastructure