An Optimized Balance of Plant for a Medium-Size PEM Electrolyzer: Design, Control and Physical Implementation

Abstract

The progressive increase in hydrogen technologies’ role in transport, mobility, electrical microgrids, and even in residential applications, as well as in other sectors is expected. However, to achieve it, it is necessary to focus efforts on improving features of hydrogen-based systems, such as efficiency, start-up time, lifespan, and operating power range, among others. A key sector in the development of hydrogen technology is its production, renewable if possible, with the objective to obtain increasingly efficient, lightweight, and durable electrolyzers. For this, scientific works are currently being produced on stacks technology improvement (mainly based on two technologies: polymer electrolyte membrane (PEM) and alkaline) and on the balance of plant (BoP) or the industrial plant (its size depends on the power of the electrolyzer) that runs the stack for its best performance. PEM technology offers distinct advantages, apart from the high cost of its components, its durability that is not yet guaranteed and the availability in the MW range. Therefore, there is an open field of research for achievements in this technology. The two elements to improve are the stacks and BoP, also bearing in mind that improving BoP will positively affect the stack operation. This paper develops the design, implementation, and practical experimentation of a BoP for a medium-size PEM electrolyzer. It is based on the realization of the optimal design of the BoP, paying special attention to the subsystems that comprise it: the power supply subsystem, water management subsystem, hydrogen production subsystem, cooling subsystem, and control subsystem. Based on this, a control logic has been developed that guarantees efficient and safe operation. Experimental results validate the designed control logic in various operating cases, including warning and failure cases. Additionally, the experimental results show the correct operation in the different states of the plant, analyzing the evolution of the hydrogen flow pressure and temperature. The capacity of the developed PEM electrolysis plant is probed regarding its production rate, wide operating power range, reduced pressurization time, and high efficiency.

Bipolar Membrane Seawater Splitting for Hydrogen Production: A Review

“…Figure a–c showcases several membrane-based electrolyzers. A proton exchange membrane (PEM) electrolyzer (Figure a) operates at lower temperatures, providing excellent current densities, fast response times, and high energy efficiency. − However, PEM electrolysis technology demands costly catalysts, perfluorinated membranes, and specialized materials due to its acidic environment, making it more expensive than other methods. − Anion exchange membrane (AEM) electrolysis combines the benefits of PEM and alkaline electrolysis (Figure b). It utilizes a thin, dense, nonporous polymer membrane to separate the electrode chambers, transferring charges via hydroxide ions, similar to alkaline water electrolysis .…”

“…A proton exchange membrane (PEM) electrolyzer ( Figure 3 a) operates at lower temperatures, providing excellent current densities, fast response times, and high energy efficiency. 60 − 63 However, PEM electrolysis technology demands costly catalysts, perfluorinated membranes, and specialized materials due to its acidic environment, making it more expensive than other methods. 60 − 63 Anion exchange membrane (AEM) electrolysis combines the benefits of PEM and alkaline electrolysis ( Figure 3 b).…”

A Review of Fuel Cell Powertrains for Long-Haul Heavy-Duty Vehicles: Technology, Hydrogen, Energy and Thermal Management Solutions

“…Bipolar plates shown in Section 3.4 serve to maintain electrical contact between opposite electrodes of series stacked fuel cells, distribute H 2 and air uniformly across cell surfaces, and effectively cool individual membrane assemblies by housing coolant channels [27,153]. The fuel cell stacks are supported by various auxiliary components for maintaining functional safety, desired power output, good system efficiency, response, operability in extreme ambient conditions and extending service life, which are together known as balance of plant (BoP) components (Figure 8) [154][155][156][157]. Power is also consumed in running these BoP components (P BoP ) decreasing the output efficiency of the FCS (η FCS ) from that of the fuel cell stack (Equation ( 1)).…”

Sun, heat and electricity. A comprehensive study of non‐pollutant alternatives to produce green hydrogen

“…Water and electricity are fed through the cell to produce hydrogen at the cathode, and oxygen at the anode. Usually, there are separators between the electrodes and the solid electrolyte, which are typically some kind of bipolar plate made of platinum (for cathode) and iridium (for anode) or a metal similarly resistant to corrosion 240‐243 …”

“…Usually, there are separators between the electrodes and the solid electrolyte, which are typically some kind of bipolar plate made of platinum (for cathode) and iridium (for anode) or a metal similarly resistant to corrosion. [240][241][242][243] Similar to previous water splitting techniques, SPE technology began to receive attention in the middle of the last century, 1959, when Grubb presented its work where he developed an experimental study about ionexchange membrane. 244 At that time, the only application found in this type of membranes was its use as membranes for the purification of salt water by electrodialysis.…”