Enabling the Green Hydrogen Supply Chain with

MATLAB and Simulink

Juan Sagarduy, MathWorks Vasco Lenzi, MathWorks

Maria Fernandez, MathWorks

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Enabling Green Hydrogen – Supply chain

Green Hydrogen Hydrogen Hydrogen

Production Distribution Consumption

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Enabling Green Hydrogen – Microgrid Water

Electricity
Hydrogen
(gas)

Multi-domain simulation

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Enabling Green Hydrogen – Motivation

Advantages Deltas

▪ 100% sustainable ▪ high energy consumption

▪ storable ▪ safety (managing H2)
▪ versatile ▪ high cost
▪ transportable

“Green hydrogen: an alternative that

reduces emissions and cares for our planet”
Iberdrola > Sustainability > Green Hydrogen Simulation
Based
Engineering

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Enabling Green Hydrogen – Key takeaways

▪ Assert feasibility
– Techno-economic analyses
– Proven concept

▪ Secure sustainable and robust operation

– Design Automation
– Optimization

▪ Collaborative Engineering
– Sharing know-how & IP
– Deployment
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Stage 1. Green Hydrogen Production
(from renewable energy to gas)

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Enabling Green Hydrogen - Challenges Production
(Micro-grid)

Component design Asset digitalization

– electrolyzer – anomaly detection
Unit – energy storage – lifetime estimation
Level
– power converter unit – prognostics development
– generator

Plant design High-level algorithmic design

System – concept evaluation – supervisory logic
Level – physical requirements – setpoint definition
– energy balance

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Enabling Green Hydrogen – Model fidelity
milliseconds (ms) seconds months
microseconds (us) minutes years

Embedded Key performance Techno-economic

development assessment Analysis (TEA)
(component) (system)

High Medium Low

fidelity fidelity fidelity

Quasi-steady
(8760)
simulations

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Enabling Green Hydrogen – TEA (solar microgrid)
Performance Techno-economic
assessment analyses

Medium Low
fidelity fidelity

Solar cell & Reduced Order

MPPT algorithm Modeling (ROM)

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Green hydrogen production – TEA (solar microgrid)

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Enabling green hydrogen – TEA (data re-use)

The irradiance data is 8760 TMY3 from Electricity price data is one day of data
National Renewable Energy Laboratory. from system operators.

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Enabling green hydrogen – TEA (outcome)

H2 production: Highest grid cost & Lowest solar resource

242 years in 500 seconds

i.e.
1 year every 2 seconds

Reduced Parallel Agile Insights

Order Models + Computing = (decision-making)

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Enabling green hydrogen – System performance

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Enabling green hydrogen – System performance
Medium
o expected H2 production & water consumption fidelity
o suitable control strategy (conditions, use of physical assets)
o energy storage (dimensioning, expected duty regime)
o planning of operations (collect – replace - maintain)

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Stage 2. Hydrogen Distribution
(from tank to consumers)

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Enabling Green Hydrogen – Challenges H2 handling and usage

(Stage 2)

Transfer
(tank-to-cell)

o Optimal components sizing

(cooling, storage, compressors)

o Reliable 24/7 software operation

o Meet critical safety requirements

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Modeling gas systems with Simscape

▪ Case study: Hydrogen Refueling Station

High
Compressor Pressure Chiller Dispenser Vehicle
Storage
950 bar - 40°C Test case:
30 bar -> 700 bar
m_H2 = 6 kg
∆t <300 s
H2 low
pressure
supply
30 bar

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Enabling green hydrogen – Case Study

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 Algorithm model and deployment on real-time controller
• Automatic code generation from models

• Reduced coding time & errors

• Hardware independent source code

• Know-how captured in single source (model)

All relevant PLCs supported

PLCs, ECU, custom hardware

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 Scalable to certification workflows ensuring highest quality & safety

▪ IEC 61508 - Safety-related systems

▪ ISO 26262 - Automotive / Motorcycle

▪ ISO 25119 - Agriculture and Forestry

▪ EN 50128 - Rail

▪ IEC 62304 - Medical

▪ IEC 61511 - Process Control

▪ DO-178 & DO-254

MATLAB and Simulink

For Verification, Validation and Test
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Enabling Green Hydrogen – Challenges H2 handling and usage

(Stage 2)

Transfer
(tank-to-cell)

o Optimal components sizing

(cooling, storage, compressors)
➢ Leverage multi-domain simulation
platform
o Reliable 24/7 software operation
➢ Develop supervisory logic
with state-of-the-art V&V capabilities
o Meet critical safety requirements
➢ Model-Based Design streamline
certification of your embedded
systems

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Stage 3. Hydrogen Consumption
(e-mobility, electrification)

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Enabling Green Hydrogen – Challenges H2 handling and usage

(Stage 2) (Stage 3)

Transfer Consumption
(tank-to-cell) (E-mobility)

o Optimal components sizing o Component-level vs system-level simulation

(cooling, storage, compressors)
➢ Leverage multi-domain simulation o Optimal system architecture
platform (e.g., fuel cell multi-stack, battery)
o Reliable 24/7 software operation
➢ Develop supervisory logic o Expensive physical prototype testing
with state-of-the-art V&V capabilities
o Meet critical safety requirements
➢ Model-Based Design streamline
certification of your embedded
systems

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Fuel Cell System in Vehicle
Fuel Cell System
Balance of Plant (BoP)

Hydrogen
Air Handling
Handling
System
Fuel Cell System
Stack
Cooling / Power
DC/DC
Thermal Distribution
Converter
Management Unit

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 Multiple Domains used to Simulate Fuel Cell Systems….
Custom Fuel Cell Domain Membran
Multispecies gas network Exchange species and
for N2,O2,H2, H2O generate elec. power & heat, N2
diffusion

Controllers

Controllers

Try it out in :
Liquid cooling system
>> sscfluids_fuel_cell 25
 … and Electrolyzers!
Moist air domain
3-species gas network
Thermal liquid (water) for O2,H2, H2O

Controllers

Try it out in :
>> ssc_electrolyzer
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High fidelity video in action

▪ Add video of high fidelity fuel cell, 1 min

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Fuel Cell System in Vehicle
Fuel Cell System
Balance of Plant (BoP) Fuel cell system operation in an FCV
Hydrogen
▪ Determine instantaneous power demand
Air Handling
System
Handling ▪ Convert power demand to current demand
Fuel Cell System
▪ Distribute current demand between battery
Stack
Cooling / Power and fuel cell
DC/DC
Thermal Distribution
Management Unit
Converter ▪ Translate current command to H2 / Air flow
commands

Driver Fuel Cell

System Electric
Motor
Environment Fuel Cell Vehicle
Stack Body

Powertrain Balance Battery

Controller of Plant

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Choose the Appropriate Fidelity Level for Fuel Cell System Modeling

Model what you need …

when you need it
Computational Time

Lookup-table
statistical model
no dynamics
Detailed first principles
Voltage vs. model with gas dynamics
current curve

Detailed first principles

model without
gas dynamics

Model Complexity and Details

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Enabling Green Hydrogen – Solution (E-mobility/fuel cells)

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System level electrified propulsion unit
▪ Explore Design Space
– Example:

3 Battery Modules
2 Fuel Cell Stacks

vs

2 Battery Modules
3 Fuel Cell Stacks

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Hardware-in-the-Loop

Development Computer Target Computer Device Under Test

Emulated Sensor
Signals, Digital
Protocols (CAN)
Ethernet

Controller
Commands

If you want to know more, register to tomorrow’ webinar (19th of May 2022):
Hardware-In-Loop Testing of Balance of Plant Controller of Fuel Cell System
Simulink Real-Time + Speedgoat in action!
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Enabling Green Hydrogen – Challenges H2 handling and usage

(Stage 2) (Stage 3)

Transfer Consumption
(tank-to-cell) (E-mobility)

o Optimal components sizing o Component-level vs system-level simulation

(cooling, storage, compressors) ➢ Flexible modelling and simulation
➢ Leverage multi-domain simulation platform
platform o Optimal system architecture
o Reliable 24/7 software operation (e.g., fuel cell multi-stack, battery)
➢ Develop supervisory logic ➢ Perform trade-off analysis and
with state-of-the-art V&V capabilities monte carlo simulations
o Meet critical safety requirements o Expensive physical prototype testing
➢ Model-Based Design streamline ➢ Reduce physical prototypes, reuse
certification of your embedded models for Hardware-in-the-Loop tests
systems

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User testimonial – Nuvera Cells

Hydrogen Is the New Diesel:

Electrifying Heavy-Duty Vehicles
with Nuvera Fuel Cells
Video

“ Using modeling and real-time simulation

enables Nuvera’s engineers to iterate
on their design quickly and allows
for experimentation without putting
a real engine at risk. “

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Collaborative Engineering– IP Protection, Deployment & Sharing

IP protection Standalone Apps Web Apps

Ref_Model.slxp Cropped picture

suggesting
MATLABscript.p integration into
custom app
Cell.sscp

Shared Libraries Service APIs Standalone FMUs

Cropped picture
.dll suggesting
scaling
production
(JS/HTML-based
app?)

Click on the boxes to learn more!

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Enabling Green Hydrogen - Conclusions

▪ Assert feasibility
– techno-economic analyses
– concept evaluation

▪ Secure sustainable and robust operation

– design automation
– optimization

▪ Collaborative Engineering
– sharing know-how
– deployment

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Call to Action

▪ Developing Hydrogen Production and Fuel Cell Applications with MATLAB

and Simulink
– In-depth videos & resources
– Customer references
▪ Additional resources
– MATLAB and Simulink for the Utilities and Energy Industry
– MATLAB and Simulink for Electric Vehicle Development
– MATLAB and Simulink for Developing Power Generation and Transmission Equipment
– MATLAB and Simulink for Verification, Validation and Test

▪ Shipping examples
– PEM Fuel Cell System (2022a)
– PEM Electrolysis System (2022a)

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Thank you!
Any questions?

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for a list of additional trademarks. Other product or brand names may be trademarks or registered trademarks of their respective holders.

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