Control system and method for monitoring electrolytic cell stack condition and extending operating life

Abstract

A method of optimizing operating life of an electrolysis system includes measuring an operating parameter of a component of the system at a first location of the electrolysis system with a first sensor to obtain a raw measurement, the raw measurement including a value and / or a rate of change of the parameter, receiving the raw measurement at a controller, the value is compared to a nominal measured value and / or the rate of change to a nominal rate of change. The method also includes diagnosing an abnormality of the component based on the value and / or the rate of change that differs from the nominal value. The method also includes outputting a message indicative of the anomaly to an operator of the electrolysis system in response to the diagnosis of the anomaly.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] Pursuant to Title 35 of the United States Code, Section 119(e), and any other applicable law or regulation, this nonprovisional application claims the benefit of and priority to U.S. Provisional Application Serial No. 63 / 346,640, filed on May 27, 2022, the entire contents of which are hereby expressly incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to electrolysis systems and, more particularly, to control systems and methods for monitoring the condition of an electrolyzer cell stack in an electrolysis system. Background Art

[0004] In an electrolysis system, the electrolyzer cell stack may degrade, resulting in a shortened potential life of the stack. For example, excessive voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, and gas humidity may cause damage to the electrolyzer cell stack, thereby shortening its life. Therefore, monitoring of various operating parameters of the system helps to maximize the life of the electrolyzer cell stack. Typical monitoring of various operating parameters within the cell stack and throughout the system remains difficult to confirm directly and is invasive (e.g., without disassembly and inspection). Therefore, it is advantageous to provide a minimally invasive system for monitoring system performance, diagnosing system problems, and predicting the life of the electrolyzer cell stack.

[0005] The present disclosure relates to systems and methods for monitoring the condition of an electrolysis system and extending the working life of the electrolysis system. Specifically, the present disclosure utilizes raw measurement sensors, soft sensors, and historical data to diagnose abnormal behavior and predict the life of electrolysis system components. Such diagnosis and prediction are performed using soft sensors and historical data at different locations within the system, eliminating the need for additional sensors and measurement equipment within the system, and also utilizing existing reliable sensing technology to obtain empirical data for analysis. Therefore, the systems and methods described herein allow for life extension while minimizing invasiveness and eliminating the need to disassemble and inspect specific components of the system. Summary of the invention

[0006] According to the present disclosure, a method for monitoring at least one operating parameter in an electrolysis system to optimize the operating life of at least one component of the electrolysis system is disclosed. The method includes measuring at least one operating parameter at a first location of the electrolysis system with a first sensor to obtain a first raw measurement value of the at least one operating parameter, the first raw measurement value including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter, and receiving the first raw measurement value at a controller, the controller including at least one computer-readable storage medium.

[0007] In some embodiments, the method further includes comparing, via a controller, at least one of (i) a first value of the first raw measurement value and a predetermined nominal measurement value or (ii) a first rate of change of the first raw measurement value and a predetermined nominal rate of change, diagnosing, via the controller, at least one anomaly of at least one component of the system based on at least one of (i) the first value of the first raw measurement value differing from the predetermined nominal measurement value by a first amount or (ii) the first rate of change of the first raw measurement value differing from the predetermined nominal rate of change by a first rate amount, and in response to the diagnosis of the at least one anomaly, outputting, via the controller, a first message indicating the at least one anomaly to an operator of the electrolysis system.

[0008] In some embodiments, the method also includes determining, via a controller, a predicted life (including a predicted life length) of at least one component based on the first raw measurement value, comparing, via the controller, the predicted life length of the at least one component with a predetermined life length, and in response to the predetermined life length differing from the predicted life length by a first amount of time, outputting, via the controller, a second message indicating the predicted life to an operator of the electrolysis system.

[0009] In some embodiments, the method further comprises calculating, via the controller, a first calculated measurement of at least one operating parameter at a second location of the electrolysis system different from the first location, the first calculated measurement comprising at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of at least one anomaly is also based on at least one of (i) the first calculated value of the first calculated measurement differs from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differs by a first calculated rate amount. The determination of a predicted life (including a predicted life length) of at least one component via the controller is based on at least one of the first raw measurement and the first calculated measurement.

[0010] In some embodiments, the method further includes shutting down the electrolysis system in response to the predetermined length of time differing from the predicted length of life by a second amount of time greater than the first amount of time.

[0011] In some embodiments, the diagnosis of the at least one anomaly is further based on at least one of an overall age of the electrolysis system, a total amount of hydrogen that has been produced by the electrolysis system, or a current operating condition of the electrolysis system.

[0012] In some embodiments, at least one operating parameter includes at least one of voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, or gas humidity, and at least one component includes at least one of an electrolyzer cell stack, a pump, a heat exchanger, a tank, or a valve of the electrolysis system.

[0013] In some embodiments, the method also includes receiving at a controller at least one historical measurement value of at least one operating parameter at a first location of the electrolysis system measured by a first sensor prior to the first raw measurement value, and calculating, via the controller, a second calculated measurement value of at least one operating parameter at a second location based at least in part on the first raw measurement value and the at least one historical measurement value.

[0014] In some embodiments, the diagnosis of at least one anomaly is further based on at least one historical measurement value differing from a predetermined nominal measurement value by a third amount, and the determination of the predicted life is further based on the first raw measurement value, the first calculated measurement value, the at least one historical measurement value, and the second calculated measurement value.

[0015] In some embodiments, the method further comprises measuring at least one operating parameter at a plurality of additional first locations of the electrolysis system different from the first location with a plurality of additional sensors to obtain additional raw measurements of the at least one operating parameter at each of the plurality of additional locations to establish a plurality of additional raw measurements, and receiving the plurality of additional raw measurements at the controller. The method may also comprise calculating, via the controller, a plurality of additional calculated measurements of the at least one operating parameter at respective additional second locations of the electrolysis system different from the first location, the plurality of additional first locations, and the additional second location based at least in part on the plurality of additional raw measurements, and determining, via the controller, a predicted life of the electrolyzer cell stack based on the first raw measurements, the first calculated measurements, at least one historical measurement, the second calculated measurements, the plurality of additional raw measurements, and the plurality of additional calculated measurements.

[0016] An electrolysis system according to another aspect of the present disclosure includes at least one component including at least one of a pump, a heat exchanger, a tank, or a valve, an electrolyzer cell stack configured to separate input water into hydrogen and oxygen, a controller including at least one computer-readable storage medium, and a first sensor. The first sensor is operably connected to the controller and configured to measure at least one operating parameter at a first location of the electrolysis system to obtain a first raw measurement value of the at least one operating parameter, the first raw measurement value including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter.

[0017] In some embodiments, the controller is configured to compare at least one of (i) a first value of the first raw measurement value with a predetermined nominal measurement value or (ii) a first rate of change of the first raw measurement value with a predetermined nominal rate of change, diagnose at least one anomaly of at least one component of the system based on at least one of (i) the first value of the first raw measurement value differs from the predetermined nominal measurement value by a first amount or (ii) the first rate of change of the first raw measurement value differs from the predetermined nominal rate of change by a first rate amount, and in response to the diagnosis of the at least one anomaly, output a first message indicating the at least one anomaly to an operator of the electrolysis system via the controller.

[0018] In some embodiments, the controller is further configured to determine a predicted life (including a predicted life length) of at least one component based on the first raw measurement value, compare the predicted life length of the at least one component with a predetermined life length, and in response to the predetermined life length differing from the predicted life length by a first amount of time, output a second message indicating the predicted life to an operator of the electrolysis system.

[0019] In some embodiments, the electrolysis system further comprises a first soft sensor configured to calculate a first calculated measurement of at least one operating parameter at a second location of the electrolysis system different from the first location, the first calculated measurement comprising at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of at least one anomaly via the controller is also based on at least one of (i) the first calculated value of the first calculated measurement differs from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differs by a first calculated rate amount. The determination of a predicted life (including a predicted life length) of at least one component via the controller is based on at least one of the first raw measurement and the first calculated measurement.

[0020] In some embodiments, the at least one operating parameter includes an amount of conductivity of water flowing through the electrolysis system, and the amount of conductivity of the water is inversely proportional to the predicted life of the electrolyzer cell stack.

[0021] In some embodiments, the amount of conductivity of the water is determined based on the ion concentration of the water.

[0022] In some embodiments, the ion concentration of the water includes a measurement of the concentration of at least one of fluorine, platinum, iron, calcium, chromium, and nickel.

[0023] In some embodiments, the first location of the electrolysis system is located downstream of the electrolysis cell stack and the second location of the electrolysis system is located downstream of the first location in the electrolysis system.

[0024] In some embodiments, the electrolysis system also includes a hydrogen separator located downstream of and fluidically connected to the electrolyzer stack of the electrolysis system; a polishing loop fluidly connected to the hydrogen separator and configured to process an exhaust stream from the hydrogen separator for recirculation to an oxygen separator, the oxygen separator being located downstream of and fluidically connected to the electrolyzer stack and downstream of and fluidically connected to the polishing loop; and a water circulation pump located downstream of and fluidically connected to the oxygen separator and configured to direct water from the oxygen separator to an input pipe of the electrolyzer stack.

[0025] In some embodiments, the first position of the electrolysis system is positioned along a first fluid line that extends between and connects the polishing circuit and the oxygen separator, and the second position of the electrolysis system is positioned along a second fluid line that extends between and connects the water circulation pump and the input pipe of the electrolysis cell.

[0026] In some embodiments, the electrolysis system also includes a second, third, and fourth sensor arranged in the polishing circuit and each operably connected to the controller, each of the second, third, and fourth sensors being configured to measure water conductivity at a third, fourth, and fifth position in the polishing circuit, respectively, and the second, third, and fourth sensors being configured to obtain second, third, and fourth raw measurements of water conductivity, respectively, and send the second, third, and fourth raw measurements to the controller.

[0027] The electrolysis system may also include a second soft sensor configured for calculations about a sixth position directly downstream of the hydrogen separator, a third soft sensor configured for calculations about a seventh position directly upstream of the oxygen separator, and a fourth soft sensor configured for calculations about an eighth position along a third fluid line extending from the water circulation pump to the polishing circuit, each of the second, third, and fourth soft sensors being configured to calculate second, third, and fourth calculated measurements of water conductivity at the sixth, seventh, and eighth positions, respectively, based at least in part on the first, second, third, and fourth raw measurements. The controller is also configured to determine a predicted life (including a predicted life length) of at least one component based on the first, second, third, and fourth raw measurements and the first, second, third, and fourth calculated measurements.

[0028] In some embodiments, the diagnosis of the at least one anomaly is further based on at least one of an overall age of the electrolysis system, a total amount of hydrogen that has been produced by the electrolysis system, or a current operating condition of the electrolysis system. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The following is a detailed description of the present disclosure in conjunction with the accompanying drawings:

[0030] Figure 1Ais a perspective view of an electrolyser stack according to the present disclosure;

[0031] Figure 1B is configured to exploit Figure 1A A schematic diagram of an electrolysis system of an electrolyzer cell stack;

[0032] Figure 1C yes Figure 1B A schematic diagram of additional parts of the electrolysis system;

[0033] Figure 2 According to one embodiment of the present disclosure, at least one operating parameter in an electrolysis system is monitored to predict Figures 1A to 1C A schematic diagram of a control system for the life of an electrolyzer cell stack of an electrolysis system;

[0034] Figure 3 yes Figure 2 A schematic diagram of a monitoring system of a control system of the invention, showing that the monitoring system is used for an electrolytic fluid circuit having two electrolyzer cell stacks;

[0035] Figure 4 yes Figure 3 A schematic diagram of various monitoring positions of a monitoring system for an electrolytic fluid circuit;

[0036] Figure 5 yes Figure 3 and Figure 4 a schematic diagram of a polishing circuit of an electrolytic fluid circuit; and

[0037] Figure 6 is a flow chart of a method of monitoring at least one operating parameter in an electrolysis system according to another aspect of the present disclosure, the method including predicting a lifetime of an electrolyzer cell stack of the electrolysis system. DETAILED DESCRIPTION

[0038] Electrochemical cells and electrolyzers provide chemical reactions that include electricity. For example, fuel cells use hydrogen and oxygen to generate electricity. Electrolyzers use water and electricity to generate hydrogen and oxygen.

[0039] An electrolyzer comprises one or more electrolytic cells that chemically generate substantially pure hydrogen and oxygen from water using electricity. The power source for the electrolyzer is typically derived from an electrical or power generation system, including renewable energy systems such as wind, solar, hydroelectric, and geothermal sources used to produce green hydrogen. In turn, the pure hydrogen produced by the electrolyzer is typically used as a fuel or energy source for those same power generation systems, such as fuel cell systems.

[0040] A typical electrolytic cell, also called an "electrolyzer cell," consists of many components compressed and bundled into a stack. The electrolytic cell includes a multi-component membrane electrode assembly (MEA) having an anode, a cathode, and an electrolyte. Typically, the anode, cathode, and electrolyte of the membrane electrode assembly (MEA) are configured in a multi-layer arrangement to activate an electrochemical reaction through contact with one or more gas diffusion layers to produce hydrogen. Gas diffusion layers (GDLs) and / or porous transport layers (PTLs) are typically located on one or both sides of the MEA. Bipolar plates (BPPs) are typically located on both sides of the GDL and separate the individual electrolytic cells of the stack from each other.

[0041] The present disclosure relates to systems, components and methods for predicting and optimizing the life of electrolyzer cells and / or stacks in an electrolysis system 200. The systems and methods include using raw measurements, soft sensors and historical data to predict the life of electrolyzer cells and / or stacks. Figure 2 In a first aspect of the present disclosure, a control system 100 ("control system") for monitoring at least one operating parameter 104 in an electrolysis system 200 is shown. The at least one operating parameter can be used to predict the life of an electrolyzer cell stack 204, 208 of the electrolysis system 200 (see Figure 3 ). Those skilled in the art will understand that Figures 2 to 5 The electrolysis system 200 of the first aspect of the present disclosure shown may be configured similarly to Figures 1A to 1C The exemplary electrolysis system 10 shown and described below may alternatively include additional or fewer components as necessitated by the design requirements of the electrolysis system 200 .

[0042] like Figure 1A and Figure 1B As shown, the electrolysis system 10 is generally configured to produce hydrogen and oxygen using water and electricity. The electrolysis system 10 generally includes one or more electrolyzer cells 80, which use electricity to produce substantially pure hydrogen 13 and oxygen 15 from deionized water 30 by chemical methods. The power supply of the electrolysis system 10 generally comes from an electric power or power generation system, including a renewable energy system for producing green hydrogen, such as wind power, solar power, hydropower, and geothermal sources. In turn, the pure hydrogen produced by the electrolysis system 10 is generally used as a fuel or energy source for those power generation systems, such as fuel cell systems. Alternatively, the pure hydrogen produced by the electrolysis system 10 can be stored for later use.

[0043] A typical electrolyzer cell 80 or electrolytic cell is composed of multiple components that are compressed and bundled to form a single component; multiple electrolyzer cells 80 can be stacked on top of each other, together with bipolar plates (BPPs) 84, 85 therebetween to form an electrolyzer cell stack (e.g. Figure 1BThe number of electrolyzer cells 80 in the electrolyzer cell stacks 11, 12 may vary depending on the amount of power required to meet the power requirements of any load (e.g., a fuel cell stack). Each electrolyzer cell stack 11, 12 may accommodate a plurality of electrolyzer cells 80 connected in series and / or in parallel. In the electrolysis system 10, the number of electrolyzer cell stacks 11, 12 may vary depending on the amount of power required to operate the electrolysis system 10 (including the electrolyzer cell stacks 11, 12).

[0044] The electrolyzer cell 80 includes a multi-component membrane electrode assembly (MEA) 81 having an electrolyte 81E, an anode 81A, and a cathode 81C. Typically, the anode 81A, cathode 81C, and electrolyte 81E of the membrane electrode assembly (MEA) 81 are configured in a multilayer arrangement to activate an electrochemical reaction through contact of water with one or more gas diffusion layers 82, 83, thereby producing hydrogen and / or oxygen. The gas diffusion layers (GDL) 82, 83, which may also be referred to as porous transport layers (PTL), are typically located on one or both sides of the MEA 81. Bipolar plates (BPP) 84, 85 are typically located on both sides of the GDL and separate the individual electrolyzer cells 80 of the electrolyzer cell stacks 11, 12 from each other. One bipolar plate 85, adjacent gas diffusion layers 82, 83, and MEA 81 may form a repeating unit 88.

[0045] like Figure 1B and Figure 1C As shown, the exemplary electrolysis system 10 may include two electrolytic cell stacks 11, 12 and a fluid circuit 10FC, which includes Figure 1B and 1C Various fluid channels are shown, and are configured to convey, inject, and discharge fluids and other components to, from, the electrolysis system 10. It should be understood by those skilled in the art that one or more of the several components within the fluid circuit 10FC, as well as more or less than two electrolyzer cell stacks 11, 12, may be utilized in the electrolysis system 10. For example, the electrolysis system 10 may include one electrolyzer cell stack 11, and in other examples, the electrolysis system 10 may include three or more electrolyzer cell stacks.

[0046] The electrolysis system 10 may include one or more types of electrolyzer cell stacks 11, 12. In the illustrative illustrated embodiment, a polymer electrolyte membrane (PEM) electrolyzer cell 80 may be utilized in the cell stacks 11, 12. The PEM electrolyzer cell 80 is typically operated at a temperature of about 4°C to about 150°C, including any specific temperature or temperature range contained therein. The PEM electrolyzer cell 80 is also typically operated at a pressure of about 100 bar or less, but pressures up to about 1000 bar are also possible (including any specific pressure or pressure range contained therein), which reduces the overall energy requirements of the system. The standard electrochemical reaction that produces hydrogen gas that occurs in the PEM electrolyzer cell 80 is as follows.

[0047] Anode: 2H2O→O2+4H + +4e –

[0048] Cathode: 4H + +4e – →2H2

[0049] Overall: 2H2O (liquid) → 2H2 + O2

[0050] In addition, a solid oxide electrolyzer cell 80 may also be utilized in the electrolysis system 10. The solid oxide electrolyzer cell 80 will operate at a temperature of about 500° C. to about 1000° C., including any specific temperature or temperature range subsumed therein. The standard electrochemical reaction that occurs in the solid oxide electrolyzer cell 80 to produce hydrogen is as follows.

[0051] Anode: 2O 2- →O2+4e –

[0052] Cathode: 2H2O→4e – +2H2+2O 2-

[0053] Overall: 2H2O (liquid) → 2H2 + O2

[0054] In addition, an AEM electrolyzer cell 80 using an alkaline medium may also be utilized. An exemplary AEM electrolyzer cell 80 is an alkaline electrolyzer cell 80. The alkaline electrolyzer cell 80 employs an aqueous solution as an electrolyte, such as a potassium hydroxide (KOH) and / or sodium hydroxide (NaOH) solution. The alkaline electrolyzer cell 80 is typically operated at an operating temperature of about 0°C to about 150°C, including any specific temperature or temperature range contained therein. The alkaline electrolyzer cell 80 is typically operated within a pressure range of about 1 bar to about 100 bar, including any specific pressure or pressure range contained therein. Typical electrochemical reactions that produce hydrogen occurring in the alkaline electrolyzer cell 80 are as follows.

[0055] Anode: 4OH - →O2+2H2O+4e –

[0056] Cathode: 4H2O+4e – →2H2+4OH -

[0057] Overall: 2H2O 2H2+O2

[0058] like Figure 1B As shown, the electrolyzer cell stack 11, 12 includes one or more electrolyzer cells 80, which use electricity to produce substantially pure hydrogen and oxygen from water through chemical methods. In turn, the pure hydrogen produced by the electrolyzer can be used as a fuel or energy source. Figure 1B As shown, the electrolyser cell stacks 11 , 12 output the generated hydrogen to a hydrogen separator 16 along a fluid connection line 13 , and also output the generated oxygen to an oxygen separator 14 along a fluid connection line 15 .

[0059] The hydrogen separator 16 can be configured to output pure hydrogen and also discharge an additional output fluid to a hydrogen discharge tank 20, which then outputs the fluid to a deionized water discharge pipe 21. The oxygen separator 14 can output a fluid to an oxygen discharge tank 24, which in turn outputs the fluid to a deionized water discharge pipe 25. It should be understood by those skilled in the art that the specific input and output of the fluid can be pure water or other fluids, such as coolants or byproducts of chemical reactions of the electrolyzer cell stacks 11, 12. For example, oxygen and hydrogen can flow from the cell stacks 11, 12 to the respective separators 14, 16. The system 10 can also include a rectifier 32 configured to convert electricity 33 flowing to the cell stacks 11, 12 from alternating current (AC) to direct current (DC).

[0060] The deionized water discharge pipes 21, 25 each output to a deionized water tank 40, which is part of the polishing circuit 36 ​​in the fluid circuit 10FC. Figure 1C When the ionized water interacts with the internal components of the electrolyzer cell stacks 11 and 12, the water containing the ions may damage the electrolyzer cell stacks 11 and 12. Figure 1C As shown in more detail, the polishing circuit 36 ​​is configured to deionize the water so that it can be used in the cell stacks 11 , 12 without damaging the cell stacks 11 , 12 .

[0061] In the illustrated embodiment, the deionized water tank 40 outputs fluid, specifically water, to a deionized water polishing pump 144. The deionized water polishing pump 144 in turn outputs water to a water polishing heat exchanger 46 for polishing and treatment. The water then flows to a deionized water resin tank 48.

[0062] The coolant is directed through the electrolysis system 10, specifically through the deionized water heat exchanger 72 which is fluidly connected to the oxygen separator 14. The coolant used to cool the water flow may also be subsequently fed to the water polishing heat exchanger 46 via the coolant inlet pipe 27 for polishing. The coolant is then fed back to the deionized water heat exchanger 72 to cool the water therein.

[0063] After the water is output from the deionized water polishing heat exchanger 46 and then enters the deionized water resin tank 48, a portion of the water can be sent to the deionized water high pressure supply pump 60. Another portion of the water can be sent to the deionized water pressure control valve 52, such as Figure 1C The water sent to the deionized water pressure control valve 52 will flow through the recirculation fluid connection pipe 54, which allows the water to flow back to the deionized water tank 40 for continued polishing.

[0064] In some embodiments, the electrolysis system 10 may be equipped with a deionized water skid for polishing the water flow to wash away the ions in the water at a faster rate. Then, the water fed into the deionized water high pressure supply pump 60 is output to the deionized water supply pipe 64, then flows into the oxygen separator 14 for recycling, and finally reused in the electrolytic cell stacks 11 and 12. Then, this process may be repeated continuously.

[0065] The electrolysis system 10 described herein may be used in stationary and / or non-mobile power systems, such as industrial applications and power plants. The electrolysis system 10 may also be implemented in conjunction with other electrolysis systems 10 .

[0066] The present electrolysis system 10 can be included in fixed or mobile applications. The electrolysis system 10 can be located in a vehicle or powertrain 400. The vehicle or powertrain 400 including the electrolysis system 10 can be an automobile, a passenger car, a bus, a truck, a train, a locomotive, an aircraft, a light vehicle, a medium vehicle, or a heavy vehicle.

[0067] In addition, it will be appreciated by those skilled in the art that the electrolysis system 10, electrolyzer stacks 11, 12, and / or electrolyzer cell 80 described in the present disclosure may be replaced with any electrochemical system, such as a fuel cell system, a fuel cell stack, and / or a fuel cell (FC), respectively. Therefore, in some embodiments, the features and aspects of the electrolysis system 10, electrolyzer stacks 11, 12, and / or electrolyzer cell 80 described and taught in the present disclosure also relate to a fuel cell system, a fuel cell stack, and / or a fuel cell (FC). In other embodiments, the features and aspects described and taught in the present disclosure are independent of the features and aspects of a fuel cell system, a fuel cell stack, and / or a fuel cell (FC), and therefore may be distinguished therefrom.

[0068] like Figure 2 As shown, the control system 100 includes a controller 110 configured to perform various calculations as described herein. The controller 110 is also configured to facilitate communication of the control system 100 via a communication network 116. The controller 110 is capable of controlling the operating functions of various components of the system 100 and other equipment and / or components included therein and in the electrolysis system 200.

[0069] The control system 100 also includes a monitoring system 130 configured to monitor various parameters 104 of the electrolysis system 200 and transmit these parameters 104 to the controller 110, such as Figure 2 Controller 110 utilizes parameters 104 of electrolysis system 200 measured and / or calculated by monitoring system 130. Controller 110 also utilizes historical data 108 of these parameters 104. Parameters 104 may be used to diagnose abnormal behavior occurring in various system components.

[0070] The parameters 104 may also be used to feed a predictive model 120, which may be embodied within the processor 112 of the controller 110, to determine the potential life of at least one of the electrolyzer cell stacks 204, 208 of the electrolysis system 200, such as Figure 2 and Figure 3 The controller 110 then outputs to the operator 190 of the system 200 what the abnormal behavior is and how to remedy the behavior, as well as outputting whether the predicted life has degraded far beyond a predetermined acceptable life of the battery stack 204 , 208 .

[0071] In an illustrative embodiment, Figure 2 As shown, the controller 110 includes a memory 111 and a processor 112. The memory 111 and the processor 112 communicate with each other. The processor 112 can be embodied as any type of computing processing tool or equipment capable of performing the functions described herein. For example, the processor 112 can be embodied as a single-core or multi-core processor, a digital signal processor, a microcontroller, or other processor or processing / control circuit.

[0072] The memory 111 may be embodied as any type of volatile or non-volatile memory or data storage capable of performing the functions described herein. In addition, the controller 110 may also include additional or alternative components, such as commonly used computer components (e.g., various input / output devices, resistors, capacitors, etc.). In other embodiments, one or more of the controllers in the illustrative controller 110 of components may be incorporated into another component, or otherwise form part of another component. For example, the memory 111 or a portion thereof may be incorporated into the processor 112.

[0073] During operation, the memory 111 may store various data and software used during operation of the controller 110, such as an operating system, applications, programs, libraries, and drivers. The memory 111 is communicatively coupled to the processor 112 via an I / O subsystem, which may be embodied as circuits and / or components that facilitate input / output operations to the processor 112, the memory 111, and other components of the controller 110. In one embodiment, the memory 111 may be directly coupled to the processor 112, for example, via an integrated memory controller hub. Furthermore, in some embodiments, the I / O subsystem may constitute part of a system on a chip (SoC) and be integrated on a single integrated circuit chip (not shown) with the processor 112, the memory 111, and / or other components of the controller 110.

[0074] The components of the communication network 116 may be configured to use any one or more communication technologies (e.g., wired, wireless, and / or power line communications) and associated protocols (e.g., Ethernet, WiMAX, 3G, 4G LTE, 5G, etc.) to enable such communications between system components and devices, including but not limited to communications between the monitoring system 130, the control system 110, and / or the operator 190. In addition, the historical data 108 can be stored in the memory 111 of the controller 110, or can be stored on a separate storage device 113 that is communicatively connected to the controller 110 via the communication network 116.

[0075] Similarly, the prediction model 112 may be stored in the memory 111 and / or processor 112 of the controller 110. Alternatively, the prediction model 112 may also be stored on a separate storage device 113 and / or executed on a separate controller (not shown) that is communicatively connected to the controller 110 via a communication network 116. In addition, diagnostic information, including nominal values, rates, and behaviors, and solutions to abnormal behaviors may also be stored in the memory 111 for processing and output to an operator 190 of the control system 100. In addition, the monitoring system 130, the historical data 108, the prediction model 112, the controller 110, and the operator 190 may all be interconnected to each other via the communication network 116 so that each of these components may exchange necessary data with each other.

[0076] In an illustrative embodiment, Figure 2 As shown, the monitoring system 130 is in communication with the controller 110 and is configured to monitor various parameters 104 of the electrolysis system 200. The monitoring system 130 transmits these parameters 104 to the controller 110 for further processing. During typical use of the electrolysis system 200, the electrolyzer cell stacks 204, 208 of the electrolysis system 200 may degrade.

[0077] Excessive amounts of a particular parameter 104, such as voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, fluid resistivity, and / or gas humidity may cause damage to the electrolyzer cell stack 204, 208, thereby shortening its life. The controller 110 is configured to correlate at least one of the parameters 104 at one or more locations within the electrolysis system 200 with component performance, including performance of the cell stack 204, 208. Continuous monitoring of at least one parameter 104 is used to diagnose problems and predict system 200 performance and potential stack life.

[0078] In an exemplary embodiment, the electrolysis system 200 includes two electrolyzer cell stacks 204, 208 and a fluid circuit 202 configured to deliver, inject, and remove fluids and other components to, from, and from the electrolysis system 200. Those skilled in the art will appreciate that one or more of the several components within the fluid circuit 202, as well as more or less than two electrolyzer cell stacks 204, 208, may be utilized in the system 200. For example, the electrolysis system 200 may include one electrolyzer cell stack 204, and in other examples, the electrolysis system 200 may include three or more electrolyzer cell stacks.

[0079] In addition, as described above, the electrolysis system 200 may be substantially similar to the electrolysis system 10. Specifically, the components of the electrolysis system 200, specifically, for example, the electrolysis cell stacks 204, 208, the connection lines 206, 210, the oxygen separator 212 and the hydrogen separator 216, the hydrogen discharge tank 220, the oxygen discharge tank 224, the various discharge pipes 221, 225, the various supply pipes 264, 268, the coolant input pipe 227 and the polishing circuit 236 and its related components (deionized water tank 240, deionized water polishing pump 244, water polishing heat exchanger 246, deionized water resin tank 248, deionized water pressure control valve 252, recirculation fluid connection pipe 254 and deionized water high pressure supply pump 260) are all configured to be similar to their corresponding components in the above-mentioned electrolysis system 10.

[0080] As described above, continued use of the electrolysis system 200 can produce abnormal behavior within components of the system 200, as well as reduce the remaining time of the life of components of the system 200, including the electrolyzer cell stacks 204, 208. In order to diagnose and predict the life of system components, the monitoring system 130 includes raw sensors, and in some embodiments, soft sensors, to determine the values ​​of various operating parameters 104 at different locations of the fluid circuit 202. As described in more detail below, the parameters 104 are sent to the controller 110 for further processing, diagnosis, and / or prediction of the life of the system 200 components. The components of the system 200 that can be evaluated for abnormal behavior and life can include any components of the system that wear over time, such as, but not limited to, pumps, heat exchangers, tanks, valves, and cell stacks 204, 208.

[0081] The electrolysis system 200 includes at least one location 132, at which a raw sensor 133 is arranged. The raw sensor is configured to obtain raw measurement values ​​of one or more parameters 104 at the location 132, such as Figure 4 The system 200 also includes at least one second location 140 at which a first calculated measurement of one or more parameters 104 at the location 140 is calculated, such as Figure 4 The calculation of the first calculated measurement value and the other calculated measurement values ​​will be described in more detail below.

[0082] In an illustrative embodiment, Figure 4 As shown, the electrolysis system 200 includes four raw measurement locations 132, 134, 136, 138, each raw measurement location having at least one raw sensor 133, 135, 137, 139 to collect detected measurements associated therewith. The embodiment of the electrolysis system 200 also includes four soft sensor locations 140, 142, 144, 146 at which calculated measurements of one or more parameters 104 are determined. Those skilled in the art will appreciate that any number of desired raw sensors 133, 135, 137, 139 and soft sensors 140, 142, 144, 146 may be utilized within the system 200 to accurately diagnose abnormal system 200 behavior and predict the life of system 200 components.

[0083] Each sensor 133, 135, 137, 139 is configured to obtain raw measurements of one or more of the parameters 104 at the corresponding location 132, 134, 136, 138 and send the measurements to the controller 110. The controller 110 then stores the measurements in the memory 111 for later use by the processor 112 to determine calculated measurements at the locations 140, 142, 144, 146. The controller 110 also facilitates diagnosis of abnormal behavior of components of the system 200 and is used by the predictive model 120 to predict the life of components of the system 200, including the battery stacks 204, 208.

[0084] The locations 132, 134, 136, 138 where the sensors 133, 135, 137, 139 are placed are the least invasive areas within the fluid circuit 202. Furthermore, the locations 132, 134, 136, 138 where the sensors 133, 135, 137, 139 are placed are areas where the sensors can be placed unobtrusively. Furthermore, the sensors 133, 135, 137, 139 can be placed in areas of the fluid circuit 202 based on the desired parameters to be measured.

[0085] For example, in an illustrative embodiment, Figures 3 to 5 As shown, the parameter 104 to be measured is the fluid conductivity of the water flowing through the fluid circuit 202. Therefore, a first sensor 133 is arranged at a first position 132 at the output pipe of the deionized water tank 240 directly between the tank 240 and the pump 244. A second sensor 135 is arranged at a second position 134 within the deionized water tank 240. A third sensor 137 is arranged at a third position 136 within the recirculating fluid connection pipe 254. A fourth sensor 139 is arranged at a fourth position 138 directly downstream of the deionized water high pressure supply pump 260. Each of these positions 132, 134, 136, 138 has sufficient available physical space within the electrolysis system 200 for placing the sensor.

[0086] In addition, in order to accurately measure the ion concentration of the water, each of the sensors 133, 135, 137, 139 is configured to measure the concentration of at least one of fluorine, platinum, iron, calcium, chromium and / or nickel ions in the water. In other embodiments, the sensors may be placed in other locations or other components of the electrolysis system that are more conducive to measuring other parameters such as temperature, pressure, flow, humidity, voltage and current. In at least some embodiments, at least one sensor located at one location is located downstream of the battery stack 204, 208 in the fluid circuit.

[0087] In addition to the raw sensors 133, 135, 137, 139, in some embodiments, the system 200 also includes soft sensors that are used to make calculated measurements at locations where it is difficult or impossible to place physical sensors. These calculated measurements can be used in conjunction with the raw measurements to improve the accuracy of determining abnormal behavior and predicting the life of the system component 200 and the stack 204, 208. In the illustrative embodiment, the controller 110 is configured to calculate the calculated measurements at the first location 140, the second location 142, the third location 144, and the fourth location 146, as shown in FIG. Figure 4 shown.

[0088] The first location 140 may be located just downstream of the deionized water heat exchanger 272. The second location 142 may be located just upstream of the water returning to the stack 204, 208 along the recirculation line 276 output from the deionized water heat exchanger 272. The third location 144 may be located just upstream of the fluid output from the stack 204, 208 entering the oxygen separator 212. The fourth location 146 may be located within the hydrogen exhaust tank 220.

[0089] In other embodiments, the location of the calculation can be located at other locations of the system 200 that are more conducive to measuring other parameters. The parameter 104 can be temperature, pressure, flow, humidity, voltage, and current. In at least some embodiments, the location of at least one soft sensor 140, 142, 144, 146 is located downstream of the raw sensor 133, 135, 137, 139 downstream of the battery stack 204, 208 in the fluid circuit 202.

[0090] In some embodiments, the soft sensing performed by the soft sensors is part of the pre-processing steps of the controller 110 that are performed prior to comparison and diagnosis of the anomalies described herein. This pre-processing may also include filtering the raw and calculated data, validating and checking the raw and calculated data, creating an exponentially weighted moving average ("EWMA") graph / chart of the data, and storing the data.

[0091] In the illustrated embodiment, the controller 110 is configured to calculate the values ​​of one or more parameters 104 at these locations 140, 142, 144, 146. The calculated or measured values ​​of the parameters 104 are predicted values ​​of the parameters 104 at these locations. The calculations may be performed by the processor 112 of the controller 110 and are based on input data received and stored in the memory 111, such as Figure 2 In some embodiments, the input data may include raw measurements received from raw sensors of the system 200 (such as the sensors 133, 135, 137, 139 described above). The input data may also include historical data 108, such as Figure 2Processor 112 utilizes known models, known algorithms, and known operating conditions of fluid circuit 202 and system 200 at these various locations to determine calculated measurements at these locations.

[0092] For example, in an embodiment measuring water conductivity, the controller 110 may utilize a mass balance model to calculate calculated measurements of water conductivity at each of the above-mentioned locations 140, 142, 144, 146. In an embodiment measuring pressure and / or fluid flow, the controller 110 may utilize known thermodynamic and hydraulic models to calculate calculated measurements of pressure and flow at each location. In an embodiment measuring temperature, the controller 110 may utilize known thermodynamic models and heat and mass balance models to calculate calculated measurements of temperature at each location. In an embodiment measuring humidity, the controller 110 may utilize known heat and mass balance models to calculate calculated measurements of humidity at each location. Those skilled in the art will appreciate that some of these models and calculations may utilize raw measurements obtained by sensors, while others may only require historical or known data to perform these calculations.

[0093] After the controller 110 performs these calculations, the controller 110 may first determine whether any of the components of the system 200 (including the battery stacks 204, 208, or any other components of the system 200 described above or known in the art) are operating within a nominal range. Specifically, the controller 110 may first compare the raw measurements taken by the sensors 133, 135, 137, 139 and compare these values ​​to the nominal measurements stored in the memory 111 of the controller 110. These measurements may include a single raw value or may include a measured rate of change (or "recovery" rate) of a particular operating parameter. The controller 110 may then, in response to a particular raw measurement value or rate of change differing from the nominal value or nominal rate of change by a predetermined allowable limit, diagnose that the difference indicates abnormal behavior of at least one component of the system 200.

[0094] In response to determining that the behavior of at least one component is abnormal, the controller 110 then outputs a message to the operator 190 of the system 100, 200, and in some embodiments, may also output suggestions to the operator 190 on how to remedy the abnormal behavior and extend the life of the at least one component. In some embodiments, if the operator 190 increases from 20% production to 100% production, several variables will change during this transient period until the state reaches a new steady state. Monitoring the first raw measurement, specifically the rate of change, enables the operator 190 to take preventive action before the operating parameter reaches a dangerous value. In some embodiments, the system 100 can also be configured to communicate from the controller 110 to the operator 190 using a control module or a human-machine interface.

[0095] For example, if it is determined that the water conductivity level is above a predetermined allowable limit on conductivity levels, the controller 110 can be configured to reduce the operating temperature of the battery stack to reduce the wear rate at the expense of reduced operating efficiency. This is an example of a "correct" answer based on the weighting of multiple factors (i.e., if the customer is most concerned about efficient production, they may choose to replace the stack). If the customer is most concerned about near-term availability, they may choose a less efficient option. In some embodiments, if system components begin to operate abnormally, the controller 110 can include these conditions in the output message to alert the operator 190, for example, of the associated loss of life due to this abnormal behavior.

[0096] Additionally, the system 100 may include recommendations from the manufacturer of the battery stack 204, 208, or other components of the system 200, or at least provide information to the operator 190 to make a fully informed risk assessment of the system 200. In some embodiments, the controller 110 also considers the calculated measurements when diagnosing abnormal behavior, specifically by utilizing the calculated measurements along with the raw measurements to determine whether the calculated measurements deviate from a predetermined allowable limit compared to a nominal value.

[0097] In some embodiments, the controller 110 is further configured to diagnose an anomaly based on a specific amount of time the system 200 has been operating. For example, the diagnosis is based on the total amount of time the system 200 has been operating since it was first used. In some embodiments, the diagnosis is based on the total amount of hydrogen produced by the system 200. Furthermore, in some embodiments, the diagnosis is based on the current operating condition of the system 200 or a specific component of the system 200. In some embodiments, the controller 110 is further configured to utilize operator requests and compare the nominal values ​​of these requests with the measured (raw or calculated) values ​​to make a diagnosis.

[0098] In some embodiments, the controller 110 is further configured to determine a predicted life of components of the system 200, including the electrolyzer cell stacks 204, 208. The controller 110 may input the raw measurements and the calculated measurements into a prediction model 120, which may be stored and executed within the processor 112 of the controller 110, such as Figure 2As shown. Based on the raw measurements and the calculated measurements, the predictive model 120 then determines the predicted life of the battery stacks 204, 208. The predictive model 120 can include many variables to determine specific predicted life information for various operator 190 specifications. For example, the predictive model 120 can simply perform an actual life calculation for the system 200, where the predicted life of one or more system 200 components is determined based on the raw measurements, based on the calculated measurements, or based on the raw measurements and the calculated measurements. Deviations of the raw measurements and the calculated measurements from the nominal values ​​may be variables that indicate the possible life of one or more system 200 components.

[0099] In some embodiments, the prediction model 120 also considers economic considerations of the operator 190 when determining the predicted life. For example, in some cases, it is not always the most economical to operate in a manner that maximizes the life of one or more system 200 components. Such circumstances may include the need to recover the capital cost of purchased equipment by producing an optimal amount of hydrogen, even though this will shorten the life. This overall approach allows the operator 190 to define their performance indicators and goals and operate towards them, and thus the prediction model 120 can utilize such predetermined factors in the life prediction and the controller 110 output to the operator 190.

[0100] The predictive model 120 may also consider the ability to work with the operator 190 to define this overall life requirement (including production factors, actual equipment life, capital cost recovery). In some embodiments, the predictive model 120 may consider the business model of the operator 190. For example, if the operator 190 is utilizing the electrolysis system 200 for grid load balancing (i.e., converting excess energy into hydrogen), the operator 190 may prioritize grid stability over electrolyzer life. This may be considered by the predictive model 120 for predicting life, and may also be considered by the controller 110 for recommending actions based on the above-mentioned diagnosis.

[0101] In an illustrative embodiment, the controller 110 is configured to utilize the raw measurements of the ion concentration of the water at the locations 132, 134, 136, 138, and the calculated measurements of the ion concentration of the water at the locations 140, 142, 144, 146 to determine the conductivity or resistivity of the water at a particular time. The controller 110 may be configured to then compare the raw measurements and / or the calculated measurements with at least one nominal value or nominal rate of change to determine whether a system 200 component such as the cell stack 204, 208 is operating abnormally, and then alert the operator 190 of the abnormality via an output message. In some embodiments, if the deviation from the nominal value is too large, the system 100 may decide to shut down the electrolysis system 200 or reduce the operating temperature of the system 200. In some embodiments, the predetermined nominal values ​​for the system 200 components and / or the stacks 204 , 208 may be industry standards and / or may be selectively determined by the manufacturer of the system 200 and / or the battery stacks 204 , 208 , and / or may be standard life lengths based on the type, size, and specifications of the system 200 components and / or the battery stacks 204 , 208 .

[0102] Similarly, the predictive model 120 can utilize raw measurements of the ion concentration of the water at locations 132, 134, 136, 138, and calculated measurements of the ion concentration of the water at locations 140, 142, 144, 146 to determine the conductivity or resistivity of the water at a particular time. The amount of conductivity of the water is inversely proportional to the predicted life of the electrolyzer cell stack, and thus the predictive model will determine that the life of the system 200 components and / or the stacks 204, 208 has been reduced based on the amount of ion concentration in the water.

[0103] The controller 110 is then configured to output a message to the operator 190 of the electrolysis system 200 in response to the predetermined expected life length of the system 200 component and / or the battery stack 204, 208 being greater than the predicted life of the system 200 component and / or the stack 204, 208 determined by the controller 110 over the first amount of time. In some embodiments, the predetermined expected life length of the system 200 component and / or the stack 204, 208 may be an industry standard and / or may be selectively determined by a manufacturer of the system 200 component and / or the battery stack 204, 208 and / or may be a standard life length based on the type, size, and specifications of the system 200 component and / or the battery stack 204, 208.

[0104] In some embodiments, in response to the predetermined expected life length being greater than the predicted life by a second amount of time, the second amount of time being greater than the first amount of time, the controller 110 is configured to shut down the electrolysis system 200 in addition to or as an alternative to sending a message to the operator 190. In some embodiments, in response to the predetermined expected life length being greater than the predicted life by a second amount of time, the second amount of time being greater than the first amount of time, the controller 110 is configured to reduce the overall operating temperature of the system 200 components and / or the cell stacks 204, 208 in addition to or as an alternative to shutting down the electrolysis system 200 and sending a message to the operator 190.

[0105] In some embodiments, if the system 200 components and / or the battery stacks 204, 208 begin to operate under non-optimal conditions, the controller 110 can include these conditions in the life prediction to alert the operator 190, for example, of the associated life loss due to this operating behavior. In addition, the system 100 can include recommendations made by the manufacturers of the system 200 components and / or the battery stacks 204, 208, or at least provide information to the operator 190 to make a fully informed risk assessment of the system 200. The information sent to the operator 190 can also be used to schedule preventive maintenance of the system 200 components.

[0106] During operation, the process of making various raw measurements at different locations in the system 200 and calculating calculated measurements at additional locations is performed continuously. As the process continues, previously determined raw measurements and calculated measurements may be used as historical data for future calculations of calculated measurements to improve the accuracy of future calculations. In some embodiments, the controller 110 may utilize machine learning and / or neural networks to continuously train itself to more accurately calculate calculated measurements and determine potential anomalies and predicted life of system 200 components and / or stacks 204, 208. In addition, as the process is continuously repeated, the operator 190 may continuously receive repeated messages, and similarly, the system 200 may be repeatedly shut down or its temperature reduced as needed.

[0107] Furthermore, in some cases, it may be beneficial for the operator 190 to have a predicted lifetime less than a predetermined lifetime time value, as opposed to other embodiments where the expected predicted lifetime is greater than a predetermined lifetime time value. The best efficiency point for a system when measured in terms of "cost of producing hydrogen" does not always coincide with the best efficiency point for a system measured in terms of lifetime or production efficiency. If the operator 190 wishes to run the system in the most economical manner possible, the longest lifetime may not always be achievable. This is a trade-off that the operator 190 (or owner of the system) needs to decide, and may result in a shorter lifetime, but may result in a lower cost scenario.

[0108] In general, it is possible to allow the operator 190 to define what the goal is, and based on a unique set of requirements, set criteria for meeting that goal, set recommendations when they deviate from this goal, and provide an indication of the life of the system at a later time if they continue on the path described. For example, running the system 200 at a cooler temperature or reducing the operating temperature of the system results in a longer life, but with less efficient performance (e.g., more costly and therefore generally not preferred). Considering all of this information holistically will allow the operator 190 to determine what the best goal is for their purposes.

[0109] Continuous monitoring of parameter 104 can be used as a predictor and monitor of system performance, allowing operator 190 to closely monitor the life of system 200 components and / or battery stacks 204, 208. Accurate monitoring can allow operator 190 to predict the end of life of battery stacks 204, 208 and better determine these dates to extend the life of expensive battery stack components. The extension of working life translates into significant savings for the operations team and achieves improved risk monitoring throughout the plant. In addition, soft sensors can be advantageously sold to existing customers without the need for modifications to existing battery stacks, and will not be limited to new equipment.

[0110] The embodiments disclosed herein will be scalable to electrolysis facilities of all sizes and may provide even more value to facilities operating battery stacks with ten or more stacks. In addition, because the systems and methods disclosed herein can be adapted to existing facilities as a software upgrade, no invasive modifications to existing systems (e.g., in advanced internal sensors) are required. The systems and methods disclosed herein can utilize existing reliable sensing technologies to acquire empirical data for the analysis described herein. The systems and methods disclosed herein can reduce customers' operating expenses and improve the ability to coordinate or stagger battery stack replacements.

[0111] like Figure 6 As shown, a method 300 for monitoring at least one operating parameter in an electrolysis system to predict the life of an electrolyzer cell stack of the electrolysis system includes a first operation 302, which is to measure at least one operating parameter using at least one sensor arranged in at least one position, and specifically, to measure at least one operating parameter using at least one sensor arranged at a first position on a fluid circuit of the electrolysis system having the first sensor to obtain a first raw measurement value of the at least one operating parameter.

[0112] The method 300 also includes a second operation 304 of pre-processing the measurements obtained from operation 302, which may include filtering the raw data, utilizing soft sensors, validating / checking the data, creating an exponentially weighted moving average graph / chart of the data, and storing the data. The second operation 304 may include receiving the first raw measurements at a controller, the controller including at least one computer-readable storage medium. The second operation 304 may also include calculating, via the controller, a first calculated measurement of at least one operating parameter of the electrolysis system at a second location different from the first location.

[0113] The method 300 also includes a third operation 306 of interpreting or comparing, via the controller, at least one of (i) the first value of the first raw measurement value to a predetermined nominal measurement value or (ii) the first rate of change of the first raw measurement value to a predetermined nominal rate of change. The comparison or interpretation may take into account a current operating condition 307 of the system, an age of the system as determined via an age counter 308, specific standards 309 of the system (including expected values ​​and levels), and owner / operator requirements. The third operation 306 may also include diagnosing, via the controller, at least one abnormality of at least one component of the system based on at least one of (i) the first value of the first raw measurement value differing from the predetermined nominal measurement value by a first amount or (ii) the first rate of change of the first raw measurement value differing from the predetermined nominal rate of change by a first rate amount.

[0114] The method 300 may also include a fourth operation 310 of transmitting an explanation and diagnosis of the anomaly to a control module or human machine interface. The method 300 also includes a fifth operation 312 of outputting a first message indicating the at least one anomaly to an operator of the electrolysis system via a controller in response to the diagnosis of the at least one anomaly. The message may define specific actions to be taken by the operator to correct the anomaly.

[0115] The following described aspects of the present disclosure are contemplated and are non-limiting:

[0116] A first aspect of the present disclosure relates to a method for monitoring at least one operating parameter in an electrolysis system to optimize the operating life of at least one component of the electrolysis system. The method includes measuring at least one operating parameter at a first location of the electrolysis system with a first sensor to obtain a first raw measurement value of the at least one operating parameter, the first raw measurement value including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter; receiving the first raw measurement value at a controller, the controller including at least one computer-readable storage medium; comparing, via the controller, at least one of (i) a first value of the first raw measurement value with a predetermined nominal measurement value or (ii) a first rate of change of the first raw measurement value with a predetermined nominal rate of change; diagnosing, via the controller, at least one abnormality of at least one component of the system based on at least one of (i) the first value of the first raw measurement value differing from the predetermined nominal measurement value by a first amount or (ii) the first rate of change of the first raw measurement value differing from the predetermined nominal rate of change by a first rate amount; and in response to the diagnosis of the at least one abnormality, outputting, via the controller, a first message indicating the at least one abnormality to an operator of the electrolysis system.

[0117] A second aspect of the present disclosure relates to an electrolysis system. The electrolysis system includes at least one component, including at least one of a pump, a heat exchanger, a tank, or a valve; an electrolyzer cell stack configured to separate input water into hydrogen and oxygen; a controller, the controller including at least one computer-readable storage medium; and a first sensor operably connected to the controller and configured to measure at least one operating parameter at a first location of the electrolysis system to obtain a first raw measurement value of the at least one operating parameter. The first raw measurement value includes at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter. The controller is configured to compare at least one of (i) a first value of the first raw measurement value and a predetermined nominal measurement value or (ii) a first rate of change of the first raw measurement value and a predetermined nominal rate of change; diagnose at least one anomaly of at least one component of the system based on at least one of (i) the first value of the first raw measurement value differing from the predetermined nominal measurement value by a first amount or (ii) the first rate of change of the first raw measurement value differing from the predetermined nominal rate of change by a first rate amount; and in response to the diagnosis of at least one anomaly, output a first message indicating the at least one anomaly to an operator of the electrolysis system via the controller.

[0118] In the first aspect of the present disclosure, the method may further include determining, via the controller, a predicted life (including a predicted life length) of at least one component based on the first raw measurement value; comparing, via the controller, the predicted life length of the at least one component with a predetermined life length; and in response to the predetermined life length differing from the predicted life length by a first amount of time, outputting, via the controller, a second message indicating the predicted life to an operator of the electrolysis system. In the first aspect of the present disclosure, the method may further include calculating, via the controller, a first calculated measurement value of at least one operating parameter at a second location of the electrolysis system different from the first location, the first calculated measurement value comprising at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of at least one anomaly may also be based on at least one of (i) a first calculated value of the first calculated measurement value differing from a predetermined nominal calculated measurement value by a first calculated amount or (ii) a first calculated rate of change of the first calculated measurement value differing by a first calculated rate amount. The determination of the predicted life (including the predicted life length) of at least one component via the controller may be based on at least one of the first raw measurement value and the first calculated measurement value.

[0119] In the first aspect of the disclosure, the method may further include shutting down the electrolysis system in response to a predetermined length of time differing from a predicted life length by a second amount of time greater than the first amount of time. In the first aspect of the disclosure, the diagnosis of at least one anomaly may also be based on at least one of the total age of the electrolysis system, the total amount of hydrogen produced by the electrolysis system, or the current operating condition of the electrolysis system. In the first aspect of the disclosure, at least one operating parameter may include at least one of voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, or gas humidity. At least one component may include at least one of an electrolyzer cell stack, a pump, a heat exchanger, a tank, or a valve of the electrolysis system.

[0120] In the first aspect of the present disclosure, the method may further include receiving at the controller at least one historical measurement of at least one operating parameter at a first location of the electrolysis system measured by the first sensor prior to the first raw measurement; and calculating, via the controller, a second calculated measurement of at least one operating parameter at a second location based at least in part on the first raw measurement and the at least one historical measurement. In the first aspect of the present disclosure, the diagnosis of at least one anomaly may also be based on at least one historical measurement differing from a predetermined nominal measurement by a third amount. The determination of the predicted life may also be based on the first raw measurement, the first calculated measurement, the at least one historical measurement, and the second calculated measurement. In a first aspect of the present disclosure, the method also includes measuring at least one operating parameter at a plurality of additional first positions of the electrolysis system different from the first position with a plurality of additional sensors to obtain additional raw measurement values ​​of the at least one operating parameter at each of the plurality of additional positions to establish a plurality of additional raw measurement values; and receiving the plurality of additional raw measurement values ​​at a controller; calculating, via the controller, a plurality of additional calculated measurement values ​​of the at least one operating parameter at corresponding additional second positions of the electrolysis system different from the first position, the plurality of additional first positions, and the additional second position based at least in part on the plurality of additional raw measurement values; and determining, via the controller, a predicted life of the electrolyzer cell stack based on the first raw measurement value, the first calculated measurement value, at least one historical measurement value, the second calculated measurement value, the plurality of additional raw measurement values, and the plurality of additional calculated measurement values.

[0121] In a second aspect of the disclosure, the controller may also be configured to determine a predicted life (including a predicted life length) of at least one component based on the first raw measurement value, compare the predicted life length of the at least one component with a predetermined life length, and in response to the predetermined life length differing from the predicted life length by a first time amount, output a second message indicating the predicted life to an operator of the electrolysis system. In a second aspect of the disclosure, the electrolysis system may also include a first soft sensor configured to calculate a first calculated measurement value of at least one operating parameter at a second location of the electrolysis system that is different from the first location. The first calculated measurement value may include at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of at least one abnormality via the controller may also be based on at least one of (i) a first calculated value of the first calculated measurement value differing from a predetermined nominal calculated measurement value by a first calculated amount or (ii) a first calculated rate of change of the first calculated measurement value differing by a first calculated rate amount. The determination of the predicted life (which may include the predicted life length) of at least one component via the controller is based on at least one of the first raw measurement value and the first calculated measurement value. In a second aspect of the disclosure, at least one operating parameter may include an amount of electrical conductivity of water flowing through the electrolysis system. The amount of electrical conductivity of the water may be inversely proportional to the predicted life of the electrolyzer cell stack. In a second aspect of the disclosure, the amount of electrical conductivity of the water may be determined based on the ion concentration of the water. In a second aspect of the disclosure, the ion concentration of the water may include a measured value of the concentration of at least one of fluorine, platinum, iron, calcium, chromium, and nickel.

[0122] In the second aspect of the present disclosure, the first position of the electrolysis system may be located downstream of the electrolyzer stack, and the second position of the electrolysis system may be located downstream of the first position in the electrolysis system. In the second aspect of the present disclosure, the electrolysis system may also include a hydrogen separator located downstream of the electrolyzer stack of the electrolysis system and fluidly connected thereto; a polishing circuit fluidly connected to the hydrogen separator and configured to process an exhaust stream from the hydrogen separator to be recycled into an oxygen separator, the oxygen separator being located downstream of the electrolyzer stack and fluidly connected thereto and being located downstream of the polishing circuit and fluidly connected thereto; and a water circulation pump located downstream of the oxygen separator and fluidly connected thereto and configured to direct water from the oxygen separator to an input pipe of the electrolyzer stack. In the second aspect of the present disclosure, the first position of the electrolysis system may be located along a first fluid line extending between the polishing circuit and the oxygen separator and interconnecting them. The second position of the electrolysis system may be located along a second fluid line extending between the water circulation pump and the input pipe of the electrolyzer and interconnecting them. In a second aspect of the present disclosure, the electrolysis system may further include a second, third, and fourth sensor disposed within the polishing loop and each operably connected to the controller. Each of the second, third, and fourth sensors may be configured to measure water conductivity at a third, fourth, and fifth position within the polishing loop, respectively, and the second, third, and fourth sensors may be configured to obtain second, third, and fourth raw measurements of water conductivity, respectively, and send the second, third, and fourth raw measurements to the controller. The electrolysis system may further include a second soft sensor configured for calculations about a sixth position just downstream of the hydrogen separator, a third soft sensor configured for calculations about a seventh position just upstream of the oxygen separator, and a fourth soft sensor configured for calculations about an eighth position along a third fluid line extending from a water circulation pump to the polishing loop. Each of the second, third, and fourth soft sensors may be configured to calculate second, third, and fourth calculated measurements of water conductivity at the sixth, seventh, and eighth positions, respectively, based at least in part on the first, second, third, and fourth raw measurements. The controller may be further configured to determine a predicted life (including a predicted life length) of the at least one component based on the first, second, third, and fourth raw measurements and the first, second, third, and fourth calculated measurements.

[0123] In the second aspect of the present disclosure, the diagnosis of the at least one abnormality may also be based on at least one of the overall age of the electrolysis system, the total amount of hydrogen that has been produced by the electrolysis system, or the current operating condition of the electrolysis system.

[0124] Although the present disclosure has been illustrated and described in detail in the drawings and foregoing text, such illustration and description should be regarded as illustrative rather than restrictive, and it should be understood that only illustrative embodiments are illustrated and described, and all changes and modifications consistent with the present disclosure should be protected.

[0125] The multiple advantages of the present disclosure arise from the various features of the methods, apparatuses, and systems described herein. It should be noted that alternative embodiments of the methods, apparatuses, and systems of the present disclosure may not include all of the features described, but still benefit from at least some of the advantages of these features. Those of ordinary skill in the art can easily design their own implementations of the methods, apparatuses, and systems that incorporate one or more features of the present invention and are within the spirit and scope of the present disclosure as defined by the appended claims.

[0126] The features illustrated or described in conjunction with an exemplary embodiment may be combined with any other features or elements of any other embodiment described herein. Such modifications and variations are intended to be included within the scope of the present disclosure. In addition, those skilled in the art will recognize that terms well known to those skilled in the art may be used interchangeably herein.

[0127] As used herein, elements or steps listed in the singular and beginning with the word "one" or "a / an" should be understood as not excluding the plural form of the elements or steps, unless such exclusion is explicitly stated. In addition, reference to "one embodiment" of the subject matter described herein is not meant to be interpreted as excluding the existence of additional embodiments that also include the listed features. The specified numerical range of units, measurements and / or values ​​includes, is substantially composed of, or is composed of all numerical values, units, measurements and / or ranges including or within these ranges and / or endpoints, regardless of whether these numerical values, units, measurements and / or ranges are clearly defined in the present disclosure.

[0128] Unless otherwise defined, the technical and scientific terms used herein have the same meanings as those generally understood by those of ordinary skill in the art to which the present disclosure belongs. As used herein, the terms "first", "second", "third", etc. do not indicate any order or importance, but are used to distinguish one element from another. The term "or" is intended to include and refer to any one or all of the listed items. In addition, the terms "connect" and "couple" are not limited to physical or mechanical connections or couplings, and may also include direct or indirect electrical connections or couplings.

[0129] In addition, unless expressly stated to the contrary, embodiments that "include," "comprise," or "have" an element or elements having a particular property may include other such elements that do not have that property. The terms "include" or "comprising" refer to compositions, compounds, formulations, or methods that include, but do not exclude, additional elements, components, and / or method steps. The term "comprising" also refers to compositions, compounds, formulations, or method embodiments of the present disclosure that include, but do not exclude, additional elements, components, and / or method steps.

[0130] The phrase "consisting of" or "consists of" refers to a mixture, composition, formulation, or method that excludes the presence of any additional elements, components, or method steps. The phrase "consisting of" refers to a compound, composition, formulation, or method in the present disclosure that excludes the presence of any additional elements, components, or method steps.

[0131] The phrases "consisting essentially of" or "consists essentially of" refer to compositions, compounds, formulations, or methods that include additional elements, components, or method steps that have no substantial effect on the characteristics of the composition, compound, formulation, or method. The phrase "consisting essentially of" also refers to compositions, compounds, formulations, or methods of the present disclosure that include additional elements, components, or method steps that have no substantial effect on the characteristics of the composition, compound, formulation, or method.

[0132] Approximate language, as used throughout the specification and claims, may be used to modify any quantitative representation that may be permissibly varied without causing a change in the basic function associated therewith. Thus, a value modified by one or more terms, such as "about" and "substantially," is not limited to the precise value specified. In some cases, approximate language may correspond to the precision of an instrument used to measure a value. Here, as well as throughout the specification and claims, range limitations may be combined and / or interchanged. Unless the context or language indicates otherwise, such ranges have been identified and include all subranges contained therein.

[0133] As used herein, the terms "may" and "maybe" indicate the possibility of occurring under a set of circumstances; possessing a particular property, characteristic, or function; and / or qualifying another verb by expressing one or more capabilities or possibilities associated with the qualifying verb. Thus, the use of "may" and "maybe" indicates that the modified term is clearly appropriate, capable, or suitable for the indicated capacity, function, or usage, while taking into account that in some circumstances, the modified term may sometimes be inappropriate, unable, or unsuitable.

[0134] It should be understood that the above description is illustrative, not restrictive. For example, the above embodiments (and / or their aspects) can be used alone, together, or in combination with each other. In addition, many modifications can be made to adapt specific situations or materials to the teachings of the subject matter described herein without departing from its scope. Although the size and type of materials described herein are intended to limit the parameters of the disclosed subject matter, they are by no means restrictive, but exemplary embodiments. After reviewing the above description, many other embodiments will be understood by those skilled in the art. Therefore, the scope of the subject matter described herein should be determined with reference to the appended claims and the full range of equivalents to which such claims are entitled.

[0135] This written description uses examples to disclose several embodiments (including the best mode) of the subject matter described herein, and also enables a person of ordinary skill in the art to practice embodiments of the disclosed subject matter, including making and using devices or systems and performing methods. The patentable scope of the subject matter described herein is defined by the claims and may include other examples that occur to a person of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if the structural elements of such other examples do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A method of monitoring at least one operating parameter in an electrolysis system to optimize the operating life of at least one component of the electrolysis system, the method comprising: measuring the at least one operating parameter at a first location of the electrolysis system with a first sensor to obtain a first raw measurement value of the at least one operating parameter, the first raw measurement value comprising at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter; receiving the first raw measurement at a controller, the controller comprising at least one computer-readable storage medium; comparing, via the controller, at least one of (i) the first value of the first raw measurement value to a predetermined nominal measurement value or (ii) the first rate of change of the first raw measurement value to a predetermined nominal rate of change; diagnosing, via the controller, at least one anomaly of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differs from the predetermined nominal measurement value by a first amount or (ii) the first rate of change of the first raw measurement differs from the predetermined nominal rate of change by a first rate amount; as well as In response to the diagnosing of the at least one anomaly, a first message indicative of the at least one anomaly is outputted to an operator of the electrolysis system via the controller.

2. The method according to claim 1, further comprising: determining, via the controller, a predicted life (including a predicted life length) of the at least one component based on the first raw measurement; comparing, via the controller, the predicted life length of the at least one component to a predetermined life length; and In response to the predetermined length of life differing from the predicted length of life by a first amount of time, a second message indicative of the predicted life is outputted to the operator of the electrolysis system via the controller.

3. The method according to claim 2, further comprising: calculating, via the controller, a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different from the first location, the first calculated measurement comprising at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter, wherein the diagnosis of the at least one anomaly is further based on at least one of (i) the first calculated value of the first calculated measurement value differs from a predetermined nominal calculated measurement value by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement value differs by a first calculated rate amount, and Wherein the determination of the predicted life (including the predicted life length) of the at least one component via the controller is based on at least one of the first raw measurement value and the first calculated measurement value.

4. The method according to claim 3, further comprising: In response to the predetermined length of time differing from the predicted length of life by a second amount of time greater than the first amount of time, shutting down the electrolysis system.

5. The method according to claim 3, wherein: The diagnosis of the at least one anomaly is also based on at least one of an overall age of the electrolysis system, a total amount of hydrogen that has been produced by the electrolysis system, or a current operating condition of the electrolysis system.

6. The method according to claim 3, wherein: The at least one operating parameter comprises at least one of voltage, current, temperature, pressure, fluid flow rate, fluid conductivity or gas humidity, and wherein the at least one component comprises at least one of an electrolyzer cell stack, a pump, a heat exchanger, a tank or a valve of the electrolysis system.

7. The method according to claim 3, further comprising: receiving, at the controller, at least one historical measurement of the at least one operating parameter at the first location of the electrolysis system measured by the first sensor prior to the first raw measurement; as well as A second calculated measurement of the at least one operating parameter at the second location is calculated via the controller based at least in part on the first raw measurement and the at least one historical measurement.

8. The method according to claim 7, wherein: The diagnosis of the at least one anomaly is further based on the at least one historical measurement value differing from the predetermined nominal measurement value by a third amount, and wherein the determination of the predicted life is further based on the first raw measurement value, the first calculated measurement value, the at least one historical measurement value, and the second calculated measurement value.

9. The method according to claim 8, further comprising: measuring the at least one operating parameter at a plurality of additional first locations of the electrolysis system different from the first location with a plurality of additional sensors to obtain additional raw measurements of the at least one operating parameter at each of the plurality of additional locations to establish a plurality of additional raw measurements; receiving, at the controller, the plurality of additional raw measurements; calculating, via the controller, a plurality of additional calculated measurements of the at least one operating parameter at respective additional second locations of the electrolysis system different from the first location, the plurality of additional first locations, and the additional second location based at least in part on the plurality of additional raw measurements; as well as The predicted life of the electrolyzer cell stack is determined, via the controller, based on the first raw measurement, the first calculated measurement, the at least one historical measurement, the second calculated measurement, the plurality of additional raw measurements, and the plurality of additional calculated measurements.

10. An electrolysis system, comprising: at least one component, the at least one component comprising at least one of a pump, a heat exchanger, a tank, or a valve; an electrolyzer cell stack configured to separate input water into hydrogen and oxygen; a controller comprising at least one computer-readable storage medium; a first sensor operably connected to the controller and configured to measure at least one operating parameter at a first location of the electrolysis system to obtain a first raw measurement value of the at least one operating parameter, the first raw measurement value comprising at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter, Wherein, the controller is configured as: comparing at least one of (i) the first value of the first raw measurement value to a predetermined nominal measurement value or (ii) the first rate of change of the first raw measurement value to a predetermined nominal rate of change; diagnosing at least one anomaly of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differs from the predetermined nominal measurement value by a first amount or (ii) the first rate of change of the first raw measurement differs from the predetermined nominal rate of change by a first rate amount; and In response to the diagnosing of the at least one anomaly, a first message indicative of the at least one anomaly is outputted to an operator of the electrolysis system via the controller.

11. The electrolysis system according to claim 10, wherein: The controller is also configured to determine a predicted life (including a predicted life length) of the at least one component based on the first raw measurement value, compare the predicted life length of the at least one component with a predetermined life length, and in response to the predetermined life length differing from the predicted life length by a first amount of time, output a second message indicating the predicted life to the operator of the electrolysis system.

12. The electrolysis system according to claim 11, further comprising: a first soft sensor configured to calculate a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different from the first location, the first calculated measurement comprising at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter, wherein the diagnosis of the at least one anomaly via the controller is further based on at least one of (i) the first calculated value of the first calculated measurement value differs from a predetermined nominal calculated measurement value by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement value differs by a first calculated rate amount, and Wherein the determination of the predicted life (including the predicted life length) of the at least one component via the controller is based on at least one of the first raw measurement value and the first calculated measurement value.

13. The electrolysis system according to claim 12, wherein: The at least one operating parameter includes an amount of conductivity of water flowing through the electrolysis system, and wherein the amount of conductivity of the water is inversely proportional to the predicted life of the electrolyzer cell stack.

14. The electrolysis system according to claim 13, wherein: The amount of the electrical conductivity of the water is determined based on the ion concentration of the water.

15. The electrolysis system according to claim 14, wherein: The ion concentration of the water includes a measurement of a concentration of at least one of fluorine, platinum, iron, calcium, chromium, and nickel.

16. The electrolysis system according to claim 12, wherein: The first location of the electrolysis system is located downstream of the electrolysis cell stack, and the second location of the electrolysis system is located downstream of the first location in the electrolysis system.

17. The electrolysis system according to claim 16, further comprising: a hydrogen separator located downstream of and fluidly connected to the electrolyzer stack of the electrolysis system; a polishing circuit fluidly connected to the hydrogen separator and configured to treat an exhaust stream from the hydrogen separator for recirculation to an oxygen separator located downstream of and fluidly connected to the electrolyzer stack and downstream of and fluidly connected to the polishing circuit; as well as A water circulation pump is located downstream of and fluidly connected to the oxygen separator and is configured to direct water from the oxygen separator to an input pipe of the electrolyzer stack.

18. The electrolysis system according to claim 17, wherein: The first position of the electrolysis system is located along a first fluid pipeline, which extends between the polishing circuit and the oxygen separator and connects them to each other, and wherein the second position of the electrolysis system is located along a second fluid pipeline, which extends between the water circulation pump and the input pipe of the electrolysis cell and connects them to each other.

19. The electrolysis system according to claim 18, further comprising: second, third, and fourth sensors disposed within the polishing loop and each operably connected to the controller, each of the second, third, and fourth sensors being configured to measure the water conductivity at a third, fourth, and fifth location, respectively, within the polishing loop, the second, third, and fourth sensors being configured to obtain second, third, and fourth raw measurements of the water conductivity, respectively, and to send the second, third, and fourth raw measurements to the controller; as well as a second soft sensor configured for calculation regarding a sixth position immediately downstream of the hydrogen separator; a third soft sensor configured for calculation with respect to a seventh position immediately upstream of the oxygen separator; and a fourth soft sensor configured for calculations regarding an eighth position along a third fluid line extending from the water circulation pump to the polishing circuit; each of the second, third and fourth soft sensors being configured to calculate second, third and fourth calculated measurements of the water conductivity at the sixth, seventh and eighth positions based at least in part on the first, second, third and fourth raw measurements, respectively, Wherein, the controller is further configured to determine the predicted life (including the predicted life length) of the at least one component based on the first, second, third and fourth raw measurements and the first, second, third and fourth calculated measurements.

20. The electrolysis system according to claim 12, wherein: The diagnosis of the at least one anomaly is also based on at least one of an overall age of the electrolysis system, a total amount of hydrogen that has been produced by the electrolysis system, or a current operating condition of the electrolysis system.

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