Collaborative optimization hydrogen production system and method based on hydrogen purity and hydrogen evolution overpotential

Abstract

The invention discloses a collaborative optimization hydrogen production system and method based on hydrogen purity and hydrogen evolution overpotential. The collaborative optimization hydrogen production system based on hydrogen purity and hydrogen evolution overpotential comprises an electrolytic bath, a hydrogen purity detection device, a power supply, an electrical parameter detection device, a first auxiliary parameter detection device and a second auxiliary parameter detection device. According to the collaborative optimization hydrogen production method based on the hydrogen purity and the hydrogen evolution overpotential, data are collected in real time, and the size and the change trend of the hydrogen evolution overpotential are mastered in real time through accurate calculation, so that real-time collaborative optimization adjustment is facilitated. According to the scheme, the purity requirements of different industrial-grade, vehicle-mounted and electronic-grade scenes can be met by detecting the hydrogen purity in real time, calculating the hydrogen evolution overpotential in real time and cooperatively optimizing and adjusting the parameters of the power supply, so that the cost of the whole hydrogen production system is reduced; when the purity or the overpotential is abnormal, the power supply can be quickly adjusted, the corrosion loss of the electrode can be reduced, the service life of the electrode is prolonged, and the annual maintenance cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of new energy technology, and in particular to a hydrogen production system and method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential. Background Technology

[0002] Hydrogen energy is a core component of current clean energy sources, and the purity requirements for hydrogen vary greatly depending on the application: The hydrogen used in the electronics industry must have a purity of 99.999% or higher, otherwise it will cause problems with semiconductor chips; the hydrogen used in vehicle fuel cells must have a purity of 99.99% or higher, otherwise it will poison and deactivate the catalyst in the battery; and the hydrogen used in industrial production must have a purity of ≥99.97%, otherwise it will affect the effectiveness of chemical reactions. The hydrogen evolution overpotential is directly related to the energy cost of hydrogen production. Data shows that for every 50 millivolts reduction in the hydrogen evolution overpotential, the energy consumption for producing one cubic meter of hydrogen can be reduced by approximately 2.5 kilowatt-hours, demonstrating a significant energy-saving effect.

[0003] Currently, there are three main electrolytic hydrogen production technologies: alkaline electrolysis, PEM electrolysis, and SOEC electrolysis. However, most hydrogen production power supplies only output a fixed voltage and current, regardless of the purity of the final hydrogen produced, the hydrogen evolution overpotential, or the energy consumption. This leads to many problems, such as the power supply parameters meeting the standards, but the hydrogen purity being substandard, or persistently high energy consumption for hydrogen production. Especially in scenarios requiring high-purity hydrogen, additional investment is needed to install purification equipment, which not only increases investment costs but also consumes extra electricity during the purification process, which takes time and can lead to the accumulation of substandard hydrogen.

[0004] Fixed-parameter hydrogen production power supplies are currently the most commonly used basic solution. The core principle is to set a fixed output voltage and current based on the rated parameters of the electrolyzer. This typically results in a stable, pure DC output, focusing only on whether the output voltage and current exceed the set range, without considering the actual conditions during the hydrogen production process. It ignores hydrogen purity, hydrogen evolution overpotential, and energy consumption. A typical operating procedure is as follows: connect the power supply and electrolyzer with wires, ensuring a secure connection to prevent poor contact from affecting power supply; manually input the rated voltage and current parameters of the electrolyzer on the power supply's control panel; start the power supply, which outputs a fixed pure DC current while its internal detection elements monitor the output voltage and current twice per second; compare the detected values ​​with preset thresholds; if within the range, maintain the current output state; if outside the range, immediately disconnect the power supply. Throughout this process, hydrogen purity is not monitored, hydrogen evolution overpotential is not calculated, and no power supply parameters are adjusted. This approach completely disregards hydrogen purity: if impurity ions are introduced into the electrolyte in the electrolyzer, or if the electrodes oxidize and age over time, the hydrogen purity will decrease. For example, the purity of industrial-grade hydrogen may drop from 99.97% to 99.95%, but the power supply cannot detect this and continues to supply power according to the original parameters, producing substandard hydrogen and causing waste. Furthermore, the energy consumption is high and cannot be improved: the fixed pure DC output cannot adapt to the dynamic reaction state on the electrode surface, resulting in a consistently high hydrogen evolution overpotential and an inability to reduce hydrogen production energy consumption. The overpotential will increase, and energy consumption will continue to rise, with no way to improve it; poor versatility: different scenarios require hydrogen of different purities, such as industrial and electronic grades, which require different power supplies. This not only requires additional money to buy new power supplies but also time to debug, affecting production; delayed fault response: it can only detect its own voltage and current parameters and cannot predict problems such as decreased hydrogen purity and increased overpotential. It only shuts down when the voltage and current exceed the threshold, which can easily lead to excessive corrosion of the electrolytic cell electrodes and increase maintenance costs.

[0005] The purity detection + independent purification combination solution is also one of the solutions currently in use. This solution is mainly used in scenarios requiring high-purity hydrogen. The core logic is: the hydrogen production power supply still provides power according to fixed parameters, while a separate device is installed to detect the hydrogen purity. If the purity does not meet the standard, a separate purification device is started for purification. There is no linkage between the power supply and the detection and purification devices. For example, a certain PEM hydrogen production system has a separate hydrogen purity detection device and a palladium membrane purification device installed. The detection device measures the purity in real time. If it meets the standard, it outputs directly; if it does not meet the standard, it is sent to the purification device for processing. However, the power supply maintains a fixed power supply regardless of whether the purity meets the standard. Typical operating procedure: The power supply outputs pure DC power at a fixed voltage and current, the electrolyzer starts producing hydrogen, and the hydrogen is transported through pipelines; the purity detection equipment monitors the hydrogen purity in real time, once per second; if the purity reaches the target value (e.g., 99.999%), the hydrogen is directly transported to the storage tank; if the purity is insufficient, the pipeline is switched to send the hydrogen to the purification equipment; the purification equipment starts working, removing impurities from the hydrogen through heating, pressurization, etc., and after purification, it is sent to the storage tank; the power supply maintains a fixed parameter output throughout the process, does not receive signals from the purity detection equipment, and does not adjust the power supply parameters, even if the purification equipment malfunctions, the power supply continues to provide power. This solution is costly and uneconomical: the investment in purification equipment accounts for a high proportion of the total investment in the hydrogen production system, and the purification process also consumes additional electricity, increasing the overall energy consumption of hydrogen production and significantly extending the investment recovery time; there is a time lag, leading to the accumulation of substandard hydrogen: from the detection of substandard purity to the stable operation of the purification equipment, there is a period of time during which substandard hydrogen produced will accumulate and need to be handled separately, increasing the operational difficulty; the purification equipment has high maintenance costs and a short lifespan: for example, the palladium membrane in the palladium membrane purification equipment needs to be replaced after about 3,000 hours of use, and the replacement cost is very high; in addition, consumables such as adsorbents also need to be replaced regularly, resulting in high annual maintenance costs; the power supply and purification equipment are not linked: when the purity is substandard, the power supply is still supplying power according to the original parameters, which will accelerate the reaction of impurities on the electrode surface, making the hydrogen purity even lower, and actually increasing the workload of the purification equipment.

[0006] Overpotential-optimized hydrogen production power supplies (non-power supply-side improvements) are also a common solution. This approach aims to reduce hydrogen production energy consumption, but the improvement doesn't lie in the power supply itself. The core logic is to reduce the hydrogen evolution overpotential by improving the electrode materials of the electrolyzer (e.g., using more expensive precious metal catalysts) and optimizing the electrolyte concentration. The power supply itself still outputs a fixed waveform and doesn't participate in any overpotential optimization. For example, in a certain PEM hydrogen production system, to reduce overpotential, precious metal catalysts were used for the electrodes, and high-purity deionized water was used for the electrolyte. However, the associated hydrogen production power supply still outputs a fixed pure DC current, without detecting overpotential or adjusting power supply parameters. Initially, due to the superior electrode materials, the overpotential is low, but over time, the electrode activity decreases, the overpotential increases again, and energy consumption rises accordingly. Typical operating procedure: The electrolyzer is pre-loaded with modified electrodes and high-purity electrolyte, and the power supply and electrolyzer are connected. The rated voltage and current parameters of the electrolyzer are input into the power supply, and the power supply is started. The power supply outputs a fixed pure DC power. Relying on the modified electrodes and electrolyte, the hydrogen evolution overpotential is low in the initial stage, and the hydrogen production energy consumption is also relatively low. After running for a period of time, the catalyst activity on the electrodes decreases, the hydrogen evolution overpotential slowly increases, and the hydrogen production energy consumption also increases. The power supply cannot detect this change and cannot adjust the power supply parameters. Only by stopping the machine and replacing the electrodes can the low energy consumption state be restored. This solution has several drawbacks: Firstly, the electrode material cost is extremely high: the precious metal catalysts used to reduce overpotential are 10-20 times more expensive than ordinary catalysts, significantly increasing the cost of the electrolyzer, which many companies cannot afford. Secondly, it cannot maintain low energy consumption in the long term: after a period of use, the activity of the catalyst on the electrode gradually decreases, the hydrogen evolution overpotential rises again, and the hydrogen production energy consumption returns to its original level, making it impossible to maintain a low energy consumption state in the long run. Thirdly, it may affect hydrogen purity: to reduce overpotential, the catalyst activity is very high, which may lead to side reactions during electrolysis, reducing hydrogen purity, making it impossible to simultaneously achieve both purity and energy consumption. Fourthly, the power supply does not participate in overpotential control: the power supply simply provides a fixed power supply, does not detect changes in overpotential, and cannot compensate for the impact of decreased catalyst activity by adjusting power supply parameters, making the entire optimization logic incomplete. Summary of the Invention

[0007] To address the above problems, this invention proposes a hydrogen production system and method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential.

[0008] To achieve the objectives of this invention, a hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential is provided, comprising: an electrolyzer, a hydrogen purity detection device, a power supply, an electrical parameter detection device, a first auxiliary parameter detection device, and a second auxiliary parameter detection device. The power supply includes: a control panel and a core control module; The power source is used to: supply power to the electrolytic cell; The electrolytic cell is used to: convert electrical energy into chemical energy, realize water electrolysis, and produce hydrogen and oxygen. The hydrogen purity detection device is used to: detect the hydrogen purity output from the electrolyzer in real time and send it to the core control module; The electrical parameter detection device is used to: detect the actual output current of the power supply and the actual voltage across the electrolytic cell, and send them to the core control module; The first auxiliary parameter detection device is used to: detect the temperature of the electrolyte in the electrolytic cell and send it to the core control module; The second auxiliary parameter detection device is used to: detect the concentration of the electrolyte in the electrolytic cell and send it to the core control module; wherein, the detection of the concentration of the electrolyte in the electrolytic cell needs to be determined according to the specific scenario: for alkaline electrolytic cells, the concentration of KOH is measured, and for PEM or SOEC electrolytic cells, the resistivity of the electrolyte is measured.

[0009] The control panel is used to: manually switch scene modes and display in real time the purity of hydrogen output from the electrolytic cell, the hydrogen evolution overpotential, the actual current output by the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell; The core control module is used to: calculate and coordinately adjust the data of each power device inside the power supply based on the type of the electrolytic cell, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, the concentration of the electrolyte in the electrolytic cell, and the purity of the hydrogen output from the electrolytic cell, so as to achieve dynamic adjustment of the adjustable pulse step wave output by the power supply.

[0010] Furthermore, the power supply adopts a hybrid architecture consisting of LLC resonant topology and full-bridge topology.

[0011] Furthermore, the associated collaborative optimization hydrogen production system also includes: a remote monitoring platform; The remote monitoring platform is used to remotely display in real time the purity of hydrogen output from the electrolytic cell, the hydrogen evolution overpotential, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell.

[0012] Furthermore, the core control module includes: a fault determination module and a fault handling module; The fault determination module is used to: determine the fault level based on a preset fault threshold; The fault handling module is used to perform corresponding processing based on the fault level.

[0013] Furthermore, the scenario modes include: industrial-grade scenarios, automotive-grade scenarios, and electronic-grade scenarios.

[0014] This invention also provides a synergistically optimized hydrogen production method based on hydrogen purity and hydrogen evolution overpotential, comprising the following steps: S1: Manually select scene mode; S2: The hydrogen purity detection device collects the purity of the hydrogen produced by the electrolyzer and sends it to the core control module of the power supply; the electrical parameter detection device collects the actual output current of the power supply and the actual voltage across the electrolyzer and sends it to the core control module of the power supply; the first auxiliary parameter detection device collects the temperature of the electrolyte in the electrolyzer and sends it to the core control module of the power supply; the second auxiliary parameter detection device collects the concentration of the electrolyte in the electrolyzer and sends it to the core control module of the power supply. S3: The core control module of the power supply calculates and obtains the hydrogen evolution overpotential based on the type of the electrolytic cell, the purity of the hydrogen produced by the electrolytic cell, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell. S4: The core control module of the power supply determines the current state of the hydrogen evolution overpotential based on preset judgment conditions; S5: The core control module of the power supply adjusts the adjustable pulse step wave output by the power supply in coordination based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential.

[0015] Furthermore, in step S3, the core control module of the power supply calculates and obtains the hydrogen evolution overpotential based on the type of the electrolyzer, the purity of the hydrogen produced by the electrolyzer, the actual output current of the power supply, the actual voltage across the electrolyzer, the temperature of the electrolyte in the electrolyzer, and the concentration of the electrolyte in the electrolyzer. The specific process includes the following: A1: Based on the type of the electrolyzer and the temperature of the electrolyte in the electrolyzer, calculate and obtain the theoretical reversible cell pressure required for the current electrolytic hydrogen production; A2: Based on the actual voltage across the electrolytic cell and the actual current output by the power supply, the total equivalent resistance of the electrolytic cell is calculated iteratively. A3: Based on the actual voltage across the electrolyzer, the theoretical reversible cell voltage required for current electrolytic hydrogen production, the actual output current of the power supply, and the total equivalent resistance of the electrolyzer, the hydrogen evolution overpotential is calculated and obtained. A4: The hydrogen evolution overpotential is finely adjusted and corrected based on the temperature and concentration of the electrolyte in the electrolytic cell.

[0016] Furthermore, in step S4, the current state of the hydrogen evolution overpotential includes: hydrogen evolution overpotential level and hydrogen evolution overpotential stability.

[0017] Furthermore, in step S5, the specific process by which the core control module of the power supply adjusts the adjustable pulse step wave output by the power supply based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential includes: The core control module of the power supply adjusts four parameters of the adjustable pulse step wave output by the power supply in coordination, based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential: pulse frequency, pulse duty cycle, voltage step size, and step duration, by adjusting the power devices inside the power supply.

[0018] Furthermore, in step S5, The pulse frequency adjustment range is 30-100 Hz; The adjustment range of the pulse duty cycle is 40%-60%; The voltage step size is adjustable within the range of 0.05-0.1 volts. The adjustment range for the staircase maintenance time is 0.5-2 seconds.

[0019] Compared with the prior art, the present invention has the following beneficial technical effects: The new hydrogen purity feedback and hydrogen evolution overpotential optimization functions improve hydrogen purity, reduce overpotential, reduce energy consumption, and reduce costs. It has multi-scenario adaptability and can meet different needs of industrial, automotive, and electronic applications without changing the power supply, greatly improving versatility and reducing equipment investment costs.

[0020] No additional purification equipment is required, reducing the overall investment cost of the hydrogen production system. Furthermore, the absence of additional energy consumption during the purification process saves electricity. Real-time feedback on hydrogen purity and dynamic adjustment of power parameters eliminate the time lag associated with purification, significantly improving the stability of continuous hydrogen supply. The elimination of consumables such as palladium membranes and adsorbents from the purification equipment also reduces maintenance costs.

[0021] By dynamically optimizing power parameters, an overpotential reduction effect comparable to that of precious metal catalysts is achieved, but without the need for expensive precious metal catalysts, thus reducing electrode material costs. The overpotential increase caused by electrode aging can be compensated by adjusting parameters. It is also linked to hydrogen purity control, avoiding side reactions caused by excessive catalyst activity, and achieving dual protection of purity and energy consumption, preventing the situation of "reduced energy consumption but unqualified purity". Attached Figure Description

[0022] Figure 1This is a schematic diagram of a module of a hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential, as exemplified by one embodiment. Figure 2 This is a schematic diagram of a hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential, as exemplified by one embodiment. Figure 3 This is a closed-loop operation logic of a hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential, as exemplified by one embodiment. Figure 4 This is a schematic diagram illustrating an adjustable pulse ladder waveform and its related parameter definitions in one embodiment. Figure 5 This is a schematic diagram of a scene switching process in one embodiment. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0024] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0025] refer to Figure 1 As shown, Figure 1 This is a schematic diagram of a module of a hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential, according to one embodiment. The synergistic optimization hydrogen production system includes: an electrolyzer, a hydrogen purity detection device, a power supply, an electrical parameter detection device, a first auxiliary parameter detection device, and a second auxiliary parameter detection device. The power supply includes: a control panel and a core control module; The power source is used to: supply power to the electrolytic cell; The electrolytic cell is used to: convert electrical energy into chemical energy, realize water electrolysis, and produce hydrogen and oxygen. The hydrogen purity detection device is used to: detect the hydrogen purity output from the electrolyzer in real time and send it to the core control module; The electrical parameter detection device is used to: detect the actual output current of the power supply and the actual voltage across the electrolytic cell, and send them to the core control module; The first auxiliary parameter detection device is used to: detect the temperature of the electrolyte in the electrolytic cell and send it to the core control module; The second auxiliary parameter detection device is used to: detect the concentration of the electrolyte in the electrolytic cell and send it to the core control module; The control panel is used to: manually switch scene modes and display in real time the purity of hydrogen output from the electrolytic cell, the hydrogen evolution overpotential, the actual current output by the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell; The core control module is used to: calculate and coordinately adjust the data of each power device inside the power supply based on the type of the electrolytic cell, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, the concentration of the electrolyte in the electrolytic cell, and the purity of the hydrogen output from the electrolytic cell, so as to achieve dynamic adjustment of the adjustable pulse step wave output by the power supply.

[0026] In one embodiment, when the electrolytic cell is an alkaline electrolytic cell, the second auxiliary parameter detection device is used to detect the KOH concentration; when the electrolytic cell is a PEM or SOEC electrolytic cell, the second auxiliary parameter detection device is used to detect the resistivity of the electrolyte in the electrolytic cell.

[0027] In one embodiment, the power supply adopts a hybrid architecture consisting of LLC resonant topology and full-bridge topology.

[0028] In one embodiment, the collaboratively optimized hydrogen production system further includes: a remote monitoring platform; The remote monitoring platform is used to remotely display in real time the purity of hydrogen output from the electrolytic cell, the hydrogen evolution overpotential, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell.

[0029] In one embodiment, the core control module includes: a fault determination module and a fault processing module; The fault determination module is used to: determine the fault level based on a preset fault threshold; The fault handling module is used to perform corresponding processing based on the fault level.

[0030] In one embodiment, the scenario modes include: industrial-grade scenario, automotive-grade scenario, and electronic-grade scenario.

[0031] refer to Figure 2 As shown, Figure 2This is a schematic diagram of a hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential, as exemplified by one embodiment. The hydrogen production method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential includes the following steps: S1: Manually select scene mode; S2: The hydrogen purity detection device collects the purity of the hydrogen produced by the electrolyzer and sends it to the core control module of the power supply; the electrical parameter detection device collects the actual output current of the power supply and the actual voltage across the electrolyzer and sends it to the core control module of the power supply; the first auxiliary parameter detection device collects the temperature of the electrolyte in the electrolyzer and sends it to the core control module of the power supply; the second auxiliary parameter detection device collects the concentration of the electrolyte in the electrolyzer and sends it to the core control module of the power supply. S3: The core control module of the power supply calculates and obtains the hydrogen evolution overpotential based on the type of the electrolytic cell, the purity of the hydrogen produced by the electrolytic cell, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell. S4: The core control module of the power supply determines the current state of the hydrogen evolution overpotential based on preset judgment conditions; S5: The core control module of the power supply adjusts the adjustable pulse step wave output by the power supply in coordination based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential.

[0032] In one embodiment, in step S3, the core control module of the power supply calculates and obtains the hydrogen evolution overpotential based on the type of the electrolyzer, the purity of the hydrogen produced by the electrolyzer, the actual output current of the power supply, the actual voltage across the electrolyzer, the temperature of the electrolyte in the electrolyzer, and the concentration of the electrolyte in the electrolyzer. The specific process includes the following: A1: Based on the type of the electrolyzer and the temperature of the electrolyte in the electrolyzer, calculate and obtain the theoretical reversible cell pressure required for the current electrolytic hydrogen production; A2: Based on the actual voltage across the electrolytic cell and the actual current output by the power supply, the total equivalent resistance of the electrolytic cell is calculated iteratively. A3: Based on the actual voltage across the electrolyzer, the theoretical reversible cell voltage required for current electrolytic hydrogen production, the actual output current of the power supply, and the total equivalent resistance of the electrolyzer, the hydrogen evolution overpotential is calculated and obtained. A4: The hydrogen evolution overpotential is finely adjusted and corrected based on the temperature and concentration of the electrolyte in the electrolytic cell.

[0033] In one embodiment, in step S4, the current state of the hydrogen evolution overpotential includes: hydrogen evolution overpotential level and hydrogen evolution overpotential stability.

[0034] In one embodiment, the specific process by which the core control module of the power supply adjusts the adjustable pulse step wave output by the power supply based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential includes: The core control module of the power supply adjusts four parameters of the adjustable pulse step wave output by the power supply in coordination, based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential: pulse frequency, pulse duty cycle, voltage step size, and step duration, by adjusting the power devices inside the power supply.

[0035] In one embodiment, in step S5, The pulse frequency adjustment range is 30-100 Hz; The adjustment range of the pulse duty cycle is 40%-60%; The voltage step size is adjustable within the range of 0.05-0.1 volts. The adjustment range for the staircase maintenance time is 0.5-2 seconds.

[0036] like Figure 3 The diagram illustrates the closed-loop operation logic of a hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential in one embodiment: Starting with power-on and scenario selection as initial conditions, parameter acquisition and hydrogen evolution overpotential calculation are executed sequentially. The hydrogen purity / hydrogen evolution overpotential status determination module determines whether the target threshold is met. If it is met, the system enters a stable output state; otherwise, it triggers purity optimization, overpotential optimization, and synergistic optimization sub-modules. The adjusted control commands are then sent back to the parameter acquisition stage, forming a closed-loop control.

[0037] To achieve precise control over hydrogen purity and hydrogen evolution overpotential, the necessary parameters must first be accurately collected. Therefore, the first step is to use a complete detection system to collect various key data related to hydrogen production.

[0038] In one embodiment, the deployment location and function of the detection device are as follows: Hydrogen purity detection device: Installed on the pipeline at the hydrogen outlet of the electrolyzer, no more than 1 meter away from the outlet, this allows for the fastest detection of the purity of freshly produced hydrogen, avoiding the introduction of impurities during pipeline transmission that could affect the test results. The device is connected to the main pipeline via a thin branch pipe, enabling real-time extraction of small amounts of hydrogen for testing without affecting the main pipeline's hydrogen delivery. Electrical parameter detection device: Installed at the output terminal of the power supply, it is used to detect the actual output current of the power supply and the actual voltage across the electrolyzer. These two parameters are the basis for calculating the hydrogen evolution overpotential and the total equivalent resistance of the electrolyzer, and must be collected accurately. Auxiliary parameter detection device: Two detection devices are installed on the electrolyte circulation pipeline of the electrolytic cell. One measures the electrolyte temperature, and the other measures the electrolyte concentration (KOH concentration for alkaline electrolytic cells, and resistivity for PEM or SOEC electrolytic cells). Temperature and concentration affect the theoretical electrolysis voltage and resistance, and are crucial for calibration calculation results. Data transmission: All data collected by the detection devices is transmitted to the core control module of the power supply through a dedicated line. Signal interference must be avoided during transmission to ensure that the data can be transmitted quickly and accurately from acquisition to transmission to the core control module.

[0039] In one embodiment, the specific requirements for data collection are as follows: Data acquisition frequency: Hydrogen purity is acquired once per second, output current and electrolyzer voltage are acquired five times per second, and electrolyte temperature and concentration are acquired once per second to ensure timely capture of parameter changes; Electrolyzer type identification: The core control module automatically determines the type of electrolyzer (alkaline, PEM, or SOEC) based on the initially acquired voltage, temperature, and concentration data, without requiring manual settings. The corresponding calculation model is automatically matched subsequently. The calculation model uses the following method: Specifically, the core control module makes judgments based on the initially acquired "voltage-temperature-concentration (resistivity)" data: If the detected "KOH concentration" + initial voltage ≈ 1.8-2.2V → match the alkaline model; If "high resistivity (≥10MΩ)" is detected cm) + initial voltage ≈ 1.6-2.0V → Matching PEM model; If "high temperature (≥600℃)" is detected + initial voltage ≈1.2-1.5V → match SOEC model.

[0040] Furthermore, by deploying detection devices and standardizing data collection procedures, key data such as hydrogen purity, power supply parameters, and electrolyte status are accurately collected, laying the foundation for subsequent calculation of hydrogen evolution overpotential and adjustment of power supply parameters, and avoiding blind power supply.

[0041] In one embodiment, the specific steps for real-time calculation of hydrogen evolution overpotential and understanding of energy consumption status are as follows: After collecting sufficient data, the core control module will calculate the hydrogen evolution overpotential in real time to accurately grasp the current energy consumption of hydrogen production, providing a basis for subsequent parameter adjustments.

[0042] The specific steps of the calculation are as follows: Step 1: Calculate the theoretical reversible cell voltage. Based on the automatically identified electrolyzer type and the collected electrolyte temperature, a specific formula is used to calculate the theoretical minimum voltage required for hydrogen production at the current temperature. For example, the theoretical voltage of an alkaline electrolyzer at 25°C is approximately 1.23 volts, while it drops slightly to around 1.21 volts when the temperature rises to 80°C. The degree to which temperature affects the theoretical voltage varies depending on the type of electrolyzer. Step 2: Calculate the total equivalent resistance of the electrolyzer. Based on the collected actual voltage and output current of the electrolyzer, and combined with the initially estimated overpotential value, the total equivalent resistance of the electrolyzer is accurately calculated through iterative calculation. Iterative calculation involves first estimating a total equivalent resistance value, then calculating the hydrogen evolution overpotential based on this value, and then correcting the total equivalent resistance value based on the overestimated hydrogen evolution overpotential value. This process is repeated several times until both the total equivalent resistance value and the hydrogen evolution overpotential value stabilize, ensuring accurate calculation results. Step 3: Calculate the final hydrogen evolution overpotential. Subtract the theoretical reversible cell voltage calculated in step 1 from the actual voltage of the electrolyzer, and then subtract the resistance loss voltage obtained by multiplying the actual output current of the output power supply by the total equivalent resistance of the electrolyzer. The remaining value is the final hydrogen evolution overpotential.

[0043] Step 4: Calibrate the hydrogen evolution overpotential. Based on the collected concentration and temperature of the electrolyte in the electrolyzer, fine-tune the calculated hydrogen evolution overpotential. For example, if the KOH concentration in the alkaline electrolyzer deviates from the standard concentration, the hydrogen evolution overpotential will change slightly. The calculation results need to be corrected according to the concentration deviation to make the value of the hydrogen evolution overpotential more accurate.

[0044] In one embodiment, the process for determining the hydrogen evolution overpotential state is as follows: Classification: Based on the overpotential control upper limit set for different scenarios (300 mV for industrial grade, 280 mV for vehicle grade, and 250 mV for electronic grade), the hydrogen evolution overpotential state is divided into three levels: normal, slightly high, and severely high. To assess stability: If the overpotential fluctuation does not exceed 5 mV for 3 consecutive seconds, the current hydrogen production reaction is relatively stable; if the fluctuation exceeds 5 mV, the reaction is unstable, and the overpotential should be stabilized first during subsequent adjustments.

[0045] By accurately calculating and monitoring the magnitude and trend of hydrogen evolution overpotential in real time, we can understand the current level of hydrogen production energy consumption, avoiding the situation where existing technologies "only know the power supply parameters but not the actual energy consumption," and providing direction for subsequent targeted adjustments to power supply parameters.

[0046] In one embodiment, the power supply parameters are adjusted in a coordinated manner based on the hydrogen purity and the hydrogen evolution overpotential state.

[0047] This is the core step of this solution. The power supply outputs an "adjustable pulsed stepped waveform," dynamically adjusting four key parameters of the waveform based on the real-time state of hydrogen purity and hydrogen evolution overpotential. This achieves synergistic optimization of both, ensuring purity meets standards while reducing energy consumption. The power supply employs a "hybrid architecture composed of LLC resonant topology and full-bridge topology," enabling flexible adjustment of the output waveform. Signals are sent through the core control module to control the internal power devices, allowing independent adjustment of four waveform parameters: pulse frequency, pulse duty cycle, voltage step size (the magnitude of each voltage rise), and stepped duration (the duration each voltage level is held). Figure 4 The diagram shown is a schematic representation of an adjustable pulse step waveform and its related parameter definitions in one embodiment.

[0048] In one embodiment, hydrogen purity is prioritized (when hydrogen purity does not meet the standard). When the hydrogen purity is detected to be lower than the target value, parameters are adjusted first to increase the hydrogen purity. Different adjustment strategies are adopted according to the severity of the hydrogen purity deviation: Slight deviation (difference ≤ 0.005%): Keep the voltage step size and step duration unchanged, increase the pulse frequency from the base value (50 Hz) to 60 Hz, and reduce the duty cycle from 50% to 45%. Increasing the frequency can suppress the adsorption of impurity ions on the electrode surface through electric field force, and reducing the duty cycle can avoid a significant increase in overpotential, thereby improving hydrogen purity while minimizing the impact on energy consumption. Moderate deviation (0.005% < difference ≤ 0.01%): Keep the voltage step size constant, shorten the step duration, increase the pulse frequency to 80 Hz, reduce the duty cycle to 42%, and at the same time reduce the switching frequency inside the power supply to reduce the influence of electromagnetic interference on the electrode reaction, making the reaction on the electrode surface more stable and reducing the generation of impurities. Severe deviation (difference > 0.01%): Maintain the voltage step size unchanged, further shorten the step duration, increase the pulse frequency to 100 Hz, reduce the duty cycle to 40%, and activate the "high-frequency pulse cleaning mode" for 10 seconds. This uses high-frequency pulses to remove impurity ions adsorbed on the electrode surface. If the purity still does not meet the standard after 10 seconds, appropriately reduce the output current by 10% and simultaneously issue an alarm to prompt staff to check the impurity concentration in the electrolyte to prevent excessive impurities from causing persistently unacceptable purity. Termination condition: When the hydrogen purity rises back to within 0.001% of the target value and remains stable for 3 seconds, the system will revert to the basic parameters corresponding to this scenario and end the purity optimization.

[0049] In one embodiment, the hydrogen evolution overpotential is preferentially optimized (when the hydrogen evolution overpotential is too high). When the hydrogen evolution overpotential is detected to exceed the control limit, the parameters are adjusted first to reduce the overpotential. Different adjustment strategies are adopted according to the severity of the high hydrogen evolution overpotential: Slightly high (exceeding the upper limit but ≤20 mV): Maintain the pulse frequency and duty cycle unchanged, increase the voltage step size from 0.05 volts to 0.08 volts, and extend the step duration to 1.5 seconds. Increasing the voltage step size optimizes the electric field distribution on the electrode surface, making the hydrogen evolution reaction smoother, accelerating the reaction rate, and thus reducing the overpotential; Severely high (exceeding the upper limit > 20 mV): Reduce the pulse frequency to 30 Hz, increase the duty cycle to 60%, increase the voltage step size to 0.1 volts, and extend the step duration to 2 seconds. A low-frequency, wide duty cycle waveform allows for a more complete reaction on the electrode surface, and combined with a larger voltage step size, it can quickly reduce the overpotential. Simultaneously, adjust auxiliary conditions according to the type of electrolyzer: appropriately increase the electrolyte circulation rate in alkaline electrolyzers, and appropriately increase the humidification rate in PEM or SOEC electrolyzers to create better conditions for the hydrogen evolution reaction. Termination condition: When the hydrogen evolution overpotential drops below the control upper limit and remains stable for 3 seconds, the current parameters are locked, and overpotential optimization ends. If the target is not met after 20 consecutive seconds of adjustment, an alarm is issued, prompting staff to check the catalyst status of the electrode, as the overpotential increase may be caused by electrode aging.

[0050] In one embodiment, synergistic optimization (when hydrogen purity meets the standard but the hydrogen evolution overpotential is too high). When the hydrogen purity is within the target range, but the hydrogen evolution overpotential is close to the upper limit of control, a synergistic optimization strategy is adopted to reduce the overpotential while ensuring purity: Adjustment logic: A "medium-frequency pulse + gradually changing duty cycle" mode is adopted. The pulse frequency is set according to the scenario (40 Hz for industrial grade, 50 Hz for automotive grade, and 60 Hz for electronic grade), the voltage step size is set to 0.07 volts, and the step duration is set to 1 second. The duty cycle gradually increases from the lower limit of the scenario's baseline value to the upper limit, increasing by 5% per second. Hydrogen purity is sampled after each adjustment. If the hydrogen purity fluctuation does not exceed 0.002%, the duty cycle continues to increase; if the hydrogen purity fluctuation exceeds 0.002%, the adjustment stops, and the current duty cycle is locked. Optimization goal: By adjusting in this way, the hydrogen evolution overpotential can be reduced without affecting purity, thereby achieving synergistic optimization of purity and energy consumption.

[0051] In one embodiment, electrode aging compensation (when electrode aging causes an increase in overpotential). When the electrodes of an electrolyzer are used for an extended period (over 3000 hours), the catalyst activity decreases, and the hydrogen evolution overpotential increases compared to its initial value. In this case, compensation is achieved by adjusting the parameters: Adjustment logic: If the overpotential increases by 30-50 mV, reduce the pulse frequency by 5 Hz and increase the duty cycle by 5%; if it increases by 50-80 mV, reduce the pulse frequency by 10 Hz, increase the duty cycle by 8%, and increase the voltage step size by 0.02 volts; if the increase exceeds 80 mV, it indicates that the electrode is severely aged and the effect of adjusting the parameters is limited, so an alarm is issued to prompt the staff to replace the electrode. Objective: To compensate for performance degradation caused by electrode aging by adjusting parameters, extend electrode lifespan, and avoid increased costs associated with premature electrode replacement. See the table below:

[0052] By adjusting parameters in a graded and targeted manner, the problems of substandard hydrogen purity and high hydrogen evolution overpotential are solved. At the same time, the optimization of one indicator is avoided, which may lead to the deterioration of another indicator. This allows the hydrogen production process to ensure product quality, reduce energy consumption, and adapt to long-term operating changes such as electrode aging.

[0053] In one embodiment, multi-scenario adaptive switching ensures stable system operation.

[0054] Different scenarios have different requirements for hydrogen purity and energy consumption. This solution can achieve adaptive switching between multiple scenarios through parameter adjustment without replacing the power supply or adding additional equipment. At the same time, it has complete monitoring and fault handling functions to ensure stable system operation.

[0055] Parameter configurations for different scenarios: Users simply need to select the corresponding target scenario (industrial grade, automotive grade, electronic grade) on the power supply's control panel, and the power supply's core control module will automatically match the corresponding parameters. The specific configuration is as follows:

[0056] The specific process of scene switching, such as Figure 5 As shown.

[0057] Trigger switching: Users can manually select the scene mode through the power control panel; Parameter transition: When switching scene modes, parameters do not change abruptly, but are adjusted linearly and gradually. For example, the pulse frequency is adjusted by 10 Hz per second, the duty cycle by 5% per second, and the voltage step size by 0.01 volts per second, to avoid sudden power changes from impacting the electrolytic cell; Switching Verification: After the scene switch is completed, hydrogen purity and hydrogen evolution overpotential are continuously measured 5 times. If both are within the parameter range of the current scene, the switch is considered successful; otherwise, the system automatically reverts to the original scene and issues an alarm. In one embodiment, the specific handling method for system monitoring and fault handling is as follows: Real-time monitoring: The power supply control panel refreshes the data every second, displaying key parameters such as the current hydrogen purity, hydrogen evolution overpotential, actual power supply output current, actual voltage across the electrolyzer, temperature of the electrolyte in the electrolyzer, and concentration of the electrolyte in the electrolyzer. It can also upload the data to a remote monitoring platform via the network for easy viewing by staff. Fault determination: Set clear fault thresholds, such as hydrogen purity being lower than the target value minus 0.01% for 5 consecutive seconds, hydrogen evolution overpotential exceeding the control limit plus 30 mV for 5 consecutive seconds, and sudden excessive fluctuations in current or voltage, all of which are judged as faults; Fault Handling: Different measures are taken according to the severity of the fault: For minor faults (such as slight purity deviation), the corresponding optimization strategy is automatically executed; for moderate faults (such as severe purity deviation), the optimization strategy is executed and the power is reduced by 10%; for severe faults (such as persistently high overpotential), the optimization strategy is executed and the power is reduced by 30%, while issuing an audible and visual alarm; for extreme faults (such as sudden rise or fall in current), the machine is immediately shut down for protection to avoid equipment damage.

[0058] It enables seamless switching between different hydrogen production scenarios, meets different hydrogen purity and energy consumption requirements, and ensures long-term stable operation of the system through comprehensive monitoring and fault handling, reducing downtime and maintenance costs.

[0059] The following table can be used to illustrate:

[0060] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0061] It should be noted that the terms "first," "second," and "third" used in the embodiments of this application are merely to distinguish similar objects and do not represent a specific order of objects. It is understood that "first," "second," and "third" can be interchanged in a specific order or sequence where permitted. It should be understood that the objects distinguished by "first," "second," and "third" can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in an order other than those illustrated or described herein.

[0062] The terms "comprising" and "having," and any variations thereof, in this application are intended to cover non-exclusive inclusion. For example, a process, method, apparatus, product, or device that includes a series of steps or modules is not limited to the steps or modules listed, but may optionally include steps or modules not listed, or may optionally include other steps or modules inherent to such processes, methods, products, or devices.

[0063] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential, characterized in that, include: Electrolytic cell, hydrogen purity detection device, power supply, electrical parameter detection device, first auxiliary parameter detection device, and second auxiliary parameter detection device; The power supply includes: a control panel and a core control module; The power source is used to: supply power to the electrolytic cell; The electrolytic cell is used to: convert electrical energy into chemical energy, realize water electrolysis, and produce hydrogen and oxygen. The hydrogen purity detection device is used to: detect the hydrogen purity output from the electrolyzer in real time and send it to the core control module; The electrical parameter detection device is used to: detect the actual output current of the power supply and the actual voltage across the electrolytic cell, and send them to the core control module; The first auxiliary parameter detection device is used to: detect the temperature of the electrolyte in the electrolytic cell and send it to the core control module; The second auxiliary parameter detection device is used to: detect the concentration of the electrolyte in the electrolytic cell and send it to the core control module; The control panel is used to: manually switch scene modes and display in real time the hydrogen purity, hydrogen evolution overpotential, actual output current of the power supply, actual voltage across the electrolytic cell, temperature of the electrolyte in the electrolytic cell, and concentration of the electrolyte in the electrolytic cell; The core control module is used to: calculate and coordinately adjust the data of each power device inside the power supply based on the type of the electrolytic cell, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, the concentration of the electrolyte in the electrolytic cell, and the purity of the hydrogen output from the electrolytic cell, so as to achieve dynamic adjustment of the adjustable pulse step wave output by the power supply.

2. The hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 1, characterized in that, The power supply adopts a hybrid architecture consisting of LLC resonant topology and full-bridge topology.

3. The hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 2, characterized in that, It also includes: remote monitoring platform; The remote monitoring platform is used to remotely display in real time the purity of hydrogen output from the electrolytic cell, the hydrogen evolution overpotential, the actual current output by the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell.

4. The hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 3, characterized in that, The core control module includes: a fault determination module and a fault handling module; The fault determination module is used to: determine the fault level based on a preset fault threshold; The fault handling module is used to perform corresponding processing based on the fault level.

5. The hydrogen production system based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 4, characterized in that, The scenario modes include: industrial-grade scenario, automotive-grade scenario, and electronic-grade scenario.

6. A hydrogen production method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential, characterized in that, Includes the following steps: S1: Manually select scene mode; S2: The hydrogen purity detection device collects the purity of the hydrogen produced by the electrolyzer and sends it to the core control module of the power supply; the electrical parameter detection device collects the actual output current of the power supply and the actual voltage across the electrolyzer and sends it to the core control module of the power supply. The first auxiliary parameter detection device collects the temperature of the electrolyte in the electrolytic cell and sends it to the core control module of the power supply. The second auxiliary parameter detection device collects the concentration of the electrolyte in the electrolytic cell and sends it to the core control module of the power supply. S3: The core control module of the power supply calculates and obtains the hydrogen evolution overpotential based on the type of the electrolytic cell, the purity of the hydrogen produced by the electrolytic cell, the actual output current of the power supply, the actual voltage across the electrolytic cell, the temperature of the electrolyte in the electrolytic cell, and the concentration of the electrolyte in the electrolytic cell. S4: The core control module of the power supply determines the current state of the hydrogen evolution overpotential based on preset judgment conditions; S5: The core control module of the power supply adjusts the adjustable pulse step wave output by the power supply in coordination based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential.

7. The hydrogen production method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 6, characterized in that, In step S3, the core control module of the power supply calculates and obtains the hydrogen evolution overpotential based on the type of the electrolyzer, the purity of the hydrogen produced by the electrolyzer, the actual output current of the power supply, the actual voltage across the electrolyzer, the temperature of the electrolyte in the electrolyzer, and the concentration of the electrolyte in the electrolyzer. The specific process includes the following: A1: Based on the type of the electrolyzer and the temperature of the electrolyte in the electrolyzer, calculate and obtain the theoretical reversible cell pressure required for the current electrolytic hydrogen production; A2: Based on the actual voltage across the electrolytic cell and the actual current output by the power supply, the total equivalent resistance of the electrolytic cell is calculated iteratively. A3: Based on the actual voltage across the electrolyzer, the theoretical reversible cell voltage required for current electrolytic hydrogen production, the actual output current of the power supply, and the total equivalent resistance of the electrolyzer, the hydrogen evolution overpotential is calculated and obtained. A4: The hydrogen evolution overpotential is finely adjusted and corrected based on the temperature and concentration of the electrolyte in the electrolytic cell.

8. The hydrogen production method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 7, characterized in that, In step S4, the current state of the hydrogen evolution overpotential includes: hydrogen evolution overpotential level and hydrogen evolution overpotential stability.

9. The hydrogen production method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 8, characterized in that, In step S5, the specific process by which the core control module of the power supply adjusts the adjustable pulse step wave output by the power supply based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential includes: The core control module of the power supply adjusts the four parameters of the adjustable pulse step wave output by the power supply by adjusting the power devices inside the power supply, based on the purity of the hydrogen produced by the electrolyzer and the current state of the hydrogen evolution overpotential. The four parameters of the adjustable pulsed staircase waveform output by the power supply include: pulse frequency, pulse duty cycle, voltage step size, and staircase duration.

10. The hydrogen production method based on the synergistic optimization of hydrogen purity and hydrogen evolution overpotential according to claim 9, characterized in that, In step S5 The pulse frequency adjustment range is 30-100 Hz; The adjustment range of the pulse duty cycle is 40%-60%; The voltage step size is adjustable within the range of 0.05-0.1 volts. The adjustment range for the staircase maintenance time is 0.5-2 seconds.

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