- Clean Generation
- Hydrogen
- Fuel Cells
- Turnkey EPC
Hydrogen & Fuel-Cell Power
PEMFC | SOFC | PAFC | MCFC | H2-Ready Turbines | Ammonia Co-Firing | Storage
Electricity from hydrogen, with water as the exhaust.
Hydrogen can be turned back into electricity in a fuel cell, burnt in a gas turbine or engine, or carried as ammonia and co-fired in a boiler. BARREL provides and coordinates hydrogen power projects from feasibility and fuel supply planning through design, safety approvals, equipment, construction and grid connection to long-term operation. Hydrogen production is covered on BARREL's green hydrogen page.
FFuel
Hydrogen or ammonia supply and storage
CConversion
Fuel cell, turbine, engine or boiler
GGrid
Backup, captive, peaking or grid supply
- Plant size
- 1 kW–100+ MW
- H2 energy (LHV)
- 33.3 kWh/kg
- Fuel-cell efficiency
- 40–60 %
- H2 blend (vol.) in many turbines
- Up to 30 %
- At point of use
- Zero CO2
Section 01
Hydrogen & Fuel-Cell Power — Overview
Hydrogen is an energy carrier, not a primary source: it has to be made first, usually by electrolysis or from natural gas, and then stored and converted back into electricity. Its value in power is that it can store energy for days or seasons, run without carbon dioxide at the point of use and replace diesel or gas where batteries alone fall short.
This page covers the power side — fuel cells, hydrogen-fired turbines and engines, ammonia co-firing and storage for power. The round-trip efficiency from electricity to hydrogen and back is modest (about 30–45 %, indicative), so hydrogen power suits long-duration, backup and hard-to-electrify duties rather than daily cycling.
1.1Routes from hydrogen to electricity
| Route | Typical size | Typical use |
|---|---|---|
| Fuel cell (PEM, SOFC, PAFC, MCFC) | 1 kW–50 MW | Backup, telecom towers, data centres, CHP, microgrids |
| Hydrogen-fired or blended gas turbine | 5–500 MW | Peaking and combined-cycle plants, industrial CHP |
| Hydrogen gas engine | 100 kW–10 MW | Gensets, CHP, remote and island grids |
| Ammonia co-firing in coal boilers | Unit size of the boiler | Cutting CO2 from existing coal plants |
| Ammonia-fired turbine or engine | Pilot to tens of MW | Emerging, early commercial |
1.2Why hydrogen in power
01
Long-duration storage
Surplus solar and wind can be stored as hydrogen for days or seasons, beyond the few hours of a battery.
02
Clean backup
Fuel cells replace diesel gensets at hospitals, data centres and telecom sites, with no smoke or noise.
03
Firm low-carbon capacity
Hydrogen-ready turbines keep dispatchable capacity on the grid while fuel shifts away from gas.
04
Decarbonising existing assets
Blending in gas turbines and ammonia co-firing in boilers cut CO2 from plants already built.
05
High efficiency at small scale
Fuel cells keep their efficiency down to a few kilowatts and at part load.
06
Local air quality
Fuel cells emit only water and heat; burners need NOx control but no SOx or particulates.
Section 02
How a Fuel Cell Makes Power
A fuel cell combines hydrogen and oxygen electrochemically: hydrogen splits at the anode, ions cross an electrolyte, electrons flow through the external circuit as current, and water forms at the cathode. A single cell gives under one volt, so hundreds are stacked in series.
2.1Stack power and hydrogen use
Electrical output
P = I × V (stack: P = I × Vcell × Ncells)
H2 needed (kg/h) = P (kW) ÷ (33.3 × η)
Hydrogen holds about 33.3 kWh per kg on a lower heating value basis. A 1 MW fuel cell at 50 % electrical efficiency therefore uses about 60 kg of hydrogen per hour (indicative).
| Symbol | Meaning |
|---|---|
| I | Stack current, A |
| Vcell | Cell voltage under load, about 0.6–0.8 V |
| Ncells | Number of cells in series |
| 33.3 | Lower heating value of hydrogen, kWh/kg (HHV about 39.4) |
| η | Electrical efficiency on LHV, 0.40–0.60 for fuel cells |
2.2Energy path in a fuel-cell plant
- H2 storage
- Pressure regulation
- Fuel-cell stack
- DC power
- Inverter
- Transformer
- Load or grid
Cell voltage falls as current rises; designers pick an operating point that balances efficiency against stack size and cost.
Section 03
Fuel-Cell Types
Fuel cells are named after their electrolyte, which sets the operating temperature, the fuels they accept and the duties they suit.
3.1Main fuel-cell families (indicative)
| Type | Electrolyte | Temperature | Electrical efficiency | Best suited to |
|---|---|---|---|---|
| PEMFC | Polymer membrane | 60–90 °C | 40–55 % | Backup, telecom, mobility, fast start-up |
| SOFC | Ceramic oxide | 600–1,000 °C | 50–65 % (CHP above 80 %) | Baseload, data centres, CHP; also runs on natural gas or biogas |
| PAFC | Phosphoric acid | 150–200 °C | 40–45 % | Commercial CHP, hospitals, campuses |
| MCFC | Molten carbonate | 600–700 °C | 45–55 % | Large stationary and utility plants |
| AFC | Alkaline solution or membrane | 60–90 °C | 50–60 % | Niche and emerging; needs pure gases |
3.2Choosing a type
01
FastLow temperature (PEM)
Starts in seconds to minutes, follows load well, needs high-purity hydrogen.
02
EfficientHigh temperature (SOFC, MCFC)
Highest efficiency and useful heat, but slow to start; suited to steady running.
03
TransitionFuel flexibility
High-temperature cells can reform natural gas or biogas internally and move to hydrogen later.
Section 04
Stationary Plants, Turbines and Co-Firing
Hydrogen power ranges from a cabinet at a telecom tower to blending in a large combined-cycle plant.
Stationary and backup fuel cells
5- Telecom tower and data-centre backup in place of diesel
- Hospital and critical-load standby
- Combined heat and power for buildings and industry
- Off-grid and island microgrids with solar and storage
- Prime power where the grid is weak
Hydrogen-ready gas turbines
5- Blending hydrogen into natural gas, often 5–30 % by volume
- Dry low-NOx combustors adapted for hydrogen's fast flame
- Diffusion burners with water or steam for higher blends
- Path to 100 % hydrogen on newer models (vendor-specific)
- Retrofit studies for existing gas plants
Hydrogen engines
4- Converted or purpose-built reciprocating gensets
- Lean-burn combustion to limit NOx
- Fast start for peaking and backup
- Blends with natural gas during transition
Ammonia co-firing
4- Ammonia injected with coal in existing boilers
- Trials at about 20 % of heat input internationally
- Burner, NOx and ammonia-slip control
- Ammonia storage and handling at the plant
Blend limits, efficiency and emissions depend on the specific turbine or engine model; the original equipment maker's statement decides what a unit can burn.
Section 05
Designing a Hydrogen Power Plant
Design starts from the duty — hours of backup, peaking or baseload — and works back to stack or turbine size, storage volume, fuel logistics and the safety layout.
- 1Define the duty: load profile, hours of autonomy, start-up time
- 2Choose the conversion route: fuel cell, turbine, engine or co-firing
- 3Size the stack or unit with margin for degradation
- 4Estimate hydrogen use and storage for the autonomy required
- 5Plan fuel supply: on-site electrolysis, tube trailers, pipeline or ammonia
- 6Lay out hazardous zones, separation distances and ventilation
- 7Design power conversion, protection and grid or load interface
- 8Integrate heat recovery where combined heat and power is useful
5.1Hydrogen storage for power (indicative)
| Storage | Pressure / state | Typical scale | Notes |
|---|---|---|---|
| Compressed cylinders and bundles | 200–300 bar | Tens of kg | Simple; for small backup systems |
| Tube trailers and high-pressure banks | 300–500 bar | Hundreds of kg | Swappable supply for remote sites |
| Medium-pressure vessels | 30–100 bar | Up to a few tonnes | Buffer beside electrolysers and plants |
| Liquid hydrogen spheres | About −253 °C | Tonnes to hundreds of tonnes | High density; boil-off and liquefaction energy |
| Ammonia tanks | Refrigerated or about 10 bar | Thousands of tonnes | Easy to store and ship; needs cracking or direct firing |
| Salt caverns and depleted fields | Underground | Thousands of tonnes | Seasonal storage where geology allows |
Section 06
Equipment, Grid Integration and Operating Modes
Fuel cells connect through inverters like solar and batteries; hydrogen turbines and engines use synchronous generators like any gas plant.
01
Standby backup
Starts on grid failure, often with a battery bridging the first seconds; runs for the hours stored on site.
02
Peaking and firming
Runs at high-price hours or when solar and wind fall, alongside batteries for short swings.
03
Baseload and CHP
High-temperature cells run steadily and supply heat to the building or process.
04
Power-to-power hybrid
Electrolyser stores surplus renewable power as hydrogen; fuel cell returns it when needed.
6.1Connection points
- Grid code compliance for inverter-based or synchronous plant
- Protection coordination and anti-islanding or planned islanding
- Metering and telemetry to the load despatch centre
- Black-start and microgrid operation where required
6.2Key equipment and balance of plant
- Fuel-cell stacks or modules in containers
- Hydrogen supply skid: regulators, filters, shut-off valves
- Air blower or compressor and humidifier (PEM)
- Cooling loop and heat-recovery exchangers
- DC/DC converters and grid-forming inverter
- Hydrogen storage vessels, manifolds and vents
- Gas detection, flame detection and emergency shutdown
- Nitrogen purge system
- Water treatment and condensate handling
- Ammonia cracker where ammonia is the carrier
- Control system, SCADA and remote monitoring
- Step-up transformer and switchgear
Section 07
Safety, Standards and Approvals
Hydrogen is light, burns with a nearly invisible flame and ignites over a wide range of mixtures, so safe design rests on leak prevention, ventilation, detection, separation distances and trained people.
In India, storage and handling of compressed and liquefied gases come under the Petroleum and Explosives Safety Organisation (PESO) through the gas cylinder and pressure-vessel rules; ammonia also falls under hazardous-chemical rules. The National Green Hydrogen Mission supports production, demand and pilots and is gradually adding standards and safety guidance.
Standards described generally
6- IEC 62282 series for fuel-cell modules and stationary systems
- ISO 22734 for water electrolysers where on site
- ISO/TR 15916 basic safety of hydrogen systems
- ISO 19880 series for hydrogen stations and components
- IEC 60079 series for equipment in explosive atmospheres
- Pressure-vessel codes such as ASME or equivalent
Typical approvals in India
6- PESO licences for storage and handling
- Factory and boiler inspectorate where applicable
- State pollution control board consent
- Fire service NOC and electrical inspectorate
- Hazard and operability study (HAZOP) and risk assessment
- Grid connectivity and metering approvals
Rules and standards for hydrogen are developing quickly; the applicable list is confirmed for each project and site with the authorities.
Section 08
Turnkey EPC Delivery
BARREL can deliver a hydrogen power plant under one contract or coordinate separate fuel, conversion and electrical packages with specialist suppliers.
Fuel package
4- Storage vessels or tanks
- Compression or supply skids
- Piping, vents and purge
- Gas and flame detection
Conversion package
4- Fuel-cell modules or turbine / engine
- Cooling and heat recovery
- Burner retrofit for co-firing
- Unit controls
Electrical package
4- Inverters or generator and AVR
- Transformer and switchgear
- Protection and SCADA
- Grid bay and metering
8.1Typical schedule (1–20 MW, indicative)
- Feasibility 2–4 mo
- FEED & safety studies 4–8 mo
- Approvals 4–9 mo
- Build & install 9–18 mo
- Commissioning 1–3 mo
Section 09
Operation and Maintenance
Fuel-cell stacks age with hours and start-stop cycles; disciplined O&M tracks voltage decay, keeps the fuel system tight and plans stack replacement.
- Cell and stack voltage monitoring for degradation
- Stack refurbishment or replacement, often after 40,000–80,000 hours (indicative)
- Leak testing of joints, valves and manifolds
- Gas detector calibration and emergency-shutdown tests
- Periodic pressure-vessel inspection and statutory renewals
- Air filter, coolant and water-treatment upkeep
- Monthly test runs of standby systems
- Combustor inspection and NOx tuning for turbines and engines
- Hydrogen purity checks against the stack maker's limits
- Operator training and safety drills
Section 10
Finance and Commercial Models
Hydrogen power costs depend mostly on the delivered price of hydrogen and the running hours; at low hours the capital cost dominates, at high hours the fuel does.
| Item | Typical range (indicative) |
|---|---|
| Fuel-cell system capital cost | Wide range; falling with scale and volume — quoted per project |
| Hydrogen use | About 55–80 kg per MWh at 40–55 % efficiency |
| Stack life | 40,000–80,000 hours depending on type and duty |
| Turbine blending cost | Modest for low blends; higher for combustor and fuel-system changes |
| Revenue and value | Avoided diesel, captive supply, CHP heat, peaking and capacity payments |
| Business models | Owner-operated, energy-as-a-service, build-own-operate, lease |
Figures are indicative for early screening only; each project needs its own fuel-supply contract, cost estimate and financial model.
Section 11
Policy, Trends and What Comes Next
India's National Green Hydrogen Mission aims to build domestic production and demand, with incentives for electrolysers and green hydrogen and support for pilot projects in power, mobility and industry. Many other countries have similar strategies.
01
Cheaper green hydrogen
Falling solar, wind and electrolyser costs are the main lever for hydrogen power economics.
02
Turbines towards 100 % H2
Makers are developing combustors for high blends and pure hydrogen.
03
Ammonia as fuel
Direct ammonia firing in turbines, engines and boilers is moving from trials to early projects.
04
Reversible cells
Solid oxide cells that work as electrolyser and fuel cell could store and return power in one unit.
05
Hydrogen hubs
Clusters sharing storage, pipelines and offtake lower costs for each user.
06
Common standards
Safety codes, certification of green hydrogen and grid rules are being aligned internationally.
Section 12
BARREL Services for Hydrogen Power
One partner from the first fuel study to years of safe operation, backed by BARREL's network of consultants, equipment makers and contractors.
- Feasibility and duty studies
- Technology selection: fuel cell, turbine, engine or co-firing
- Hydrogen and ammonia supply planning
- FEED, HAZOP and safety layout
- Approvals and licence support
- Equipment sourcing and vendor evaluation
- Turnkey EPC / EPCM
- Grid connection and protection
- Owner's engineer and lender's engineer
- Project finance facilitation
- O&M, monitoring and stack management
- Retrofit studies for existing gas and coal plants
Project desk
Build your hydrogen power project with BARREL
From the first fuel study to clean, firm power.
Replacing diesel backup, planning a fuel-cell plant, testing hydrogen blending in a gas turbine or studying ammonia co-firing — tell us about the site and duty and we will respond with the next steps.
Project categories
- Fuel-cell backup
- Stationary fuel-cell plant
- Fuel-cell CHP
- Hydrogen-ready gas turbine
- Hydrogen engine
- Ammonia co-firing