Services
System design and prototyping
Our Center offers support to companies and institutions in the design and prototyping of components and systems through a complete range of services that includes modelling, safety and control aspects, and feasibility studies.
Check our services and contact us at [email protected]!
Digital Twinning
- Digitalisation of systems and components employing advanced models
- Development of advanced lightweight models for optimization and control employing data-driven and hybrid approaches
- Degradation and stress models for system control (PHM)
- Optimization of components employing a ensamble of modeling techniques: CFD, FEM, process design, reduced order models, dynamic modelling, coupling with techno-economic and sustainability assessment
Component Design & Mechanical Prototyping
- Technical specification definition based on state-of-the-art analysis
- Material screening, selection, and validation
- Structural analysis including FEM (mechanical resistance, fatigue, pressure vessels, etc.)
- Sealing studies (gaskets, O-rings, leak-tightness, flange connections, permeation)
- CFD and multiphysical modelling of components for hydrogen and battery technologies
- Development of technical drawings, Bill of Materials (BoM), and H&M balancing
- Mechanical prototyping of cell and stacks for flow batteries, hydrogen systems and test benches
- Product design and first prototype manufacturing
- Procedures for system use and operation
System Engineering & Integration
- Steady-state and dynamic modelling of integrated systems
- hydrogen technologies: metal hydride storage, electrolyser, fuel cell;
- flow battery technologies: stacks, tanks, BoP;
- hybrid systems: BESS, hydrogen conversion, Supercapacitor
- Optimisation of plant layout to recover thermal and mass flows, improve response time (idle, ramp-up)
- Evaluation on re-purposing, refurbishment, or recycling of EOL batteries from mobility and stationary applications and BESS design for 2-nd use.
- Evaluation of integration of hydrogen and green gases into industrial processes, integrating renewable sources and designing process feasibility
- Development of PFD, P&ID, 3D sketches, electrical schemes, and control/safety logic
- Compliance with EU directives (PED, Machinery, ATEX)
- Preliminary risk analysis and support for HAZOP studies
- Cost estimation and scalability analysis
Safety aspects in hydrogen, battery and energy systems
The Center can support companies and institutions working on hydrogen, batteries and energy systems through advanced safety engineering and risk assessment including:
- Hazard Identification and HAZOP studies for hydrogen systems and infrastructures
- Quantitative Risk Assessment using Bayesian Network methodologies
- Risk and consequence analysis using HyRAM+ for hydrogen technologies and refueling applications
- Evaluation studies of hydrogen leakages both in confined and open environments
- Safety assessment of electrolyzers, fuel cells, hydrogen storage and transport systems
- Safety tests on li-ion and next-generation battery cells
- Development of safety concepts, mitigation measures and emergency response strategies
- Support for experimental facilities, pilot plants and hydrogen testbeds
- Technical safety support within research and industrial projects.
Control aspects for hydrogen systems
Control system engineering
- State Machine
Modular, event-driven architecture managing operational modes across start-up, steady-state, and shutdown sequences for all test bench configurations - Safety State Machine
Dedicated safety layer with hard-wired interlocks and configurable alarm thresholds, ensuring safe operation of hydrogen and electrochemical systems - Control Loops
Baseline PID implementation with ongoing development of advanced control algorithms; structured as a modular library for rapid deployment across different DUTs - Component selection and signal mapping
Structured Component selection signal mapping between sensors, actuators and control units; reconfigurable to support different test bench layouts and device-under-test requirements
Prototyping activities:
- Proprietary Control Software
In-house developed, modular and highly flexible
Rapid reconfiguration of: I/O mapping, interlock logic, and automated test procedures.
Designed for rapid prototyping and validation of control strategies.
High adaptability across different application scenarios. - Control Algorithm Development
Current implementation: baseline PID controller
Ongoing development of a modular library of advanced control algorithms.
Research activities:
- Modeling for Control
Transition toward lightweight, real-time-oriented models - Hardware-in-the-Loop (HiL) Framework
Development of HiL platforms for enhanced validation ofcontrol strategies - Advanced Control Design
Research interest on advanced control techniques for performance optimization. Focus on model-based and data-driven approaches - Diagnostics & Prognostics
Solutions for: diagnostics, prognostics, state-of-health estimation.
Feasibility studies
- Techno‑economic analysis (TEA) and life cycle assessment (LCA) for scalability.
More information in the Technical Consultancies webpage - Life cycle sustainability assessment of hydrogen systems and support to development of sustainability by design
- Preliminary and detailed feasibility studies for hydrogen solutions in industrial contexts
- Integration consultancy for hydrogen systems in real applications.