Power supply for an electro-synthetic unit or an electro-energetic unit

Abstract

Systems and methods for supplying power to an electrosynthesis unit are disclosed. A traction inverter is electrically connected to the electrosynthesis unit. The traction inverter includes a control system. The control system is configured to operate the traction inverter in reverse, such that alternating current (AC) input to the traction inverter is converted to direct current (DC) output from the traction inverter, thereby supplying power to the electrosynthesis unit.

Description

Technical Field

[0001] This invention broadly relates to power sources; and more specifically to power sources for electrochemical units such as electro-synthetic cells or electro-energy cells. Exemplary embodiments relate to systems and / or methods for supplying power to electro-synthetic cells or electro-energy cells (such as industrial unit stacks), wherein the architecture of individual units allows a number of units to be stacked together to efficiently constitute a single electro-synthetic device or apparatus or electro-energy device or apparatus. Background Technology

[0002] An electrical energy unit is an electrochemical unit that generates electricity for use outside the unit over a continuous period of time. The difference between an electrical energy unit and other primary units is that they require a constant external supply of reactants. The products of the electrochemical reaction must also be continuously removed from such a unit. Unlike a battery, an electrical energy unit does not store chemical or electrical energy within itself.

[0003] Examples of power units include, but are not limited to, polymer electrolyte membrane (PEM) fuel units, alkaline fuel units, and ammonia fuel units.

[0004] An electrosynthesis unit can be similarly considered as an electrochemical unit that produces one or more chemical substances over a sustained period of time for use outside the unit. The chemical substances can be in gaseous, liquid, or solid form. Like an electrical energy unit, an electrosynthesis unit requires a constant supply of reactants and a constant removal of products. Typically, an electrosynthesis unit may also require a constant input of electrical energy.

[0005] Examples of electrosynthesis units include, but are not limited to: water electrolysis units, chlor-alkali units, and units used to produce hydrogen peroxide, ammonia, etc.

[0006] Another characteristic of electrosynthesis units or electrical energy units is that their operation typically involves large quantities of reactants and products. Such units require a continuous feed of large quantities of reactants while simultaneously requiring the continuous removal of large quantities of products.

[0007] Operating electrical and electrosynthesis units involves significant amounts of electrical energy. Therefore, a key challenge in developing these units is to make them as energy-efficient as possible during operation. This can be achieved in part by minimizing their impedance. Impedance is the barrier that a unit circuit presents to the flow of current. A well-known method for minimizing impedance is to employ a unit architecture in which the anode and cathode electrodes are positioned facing each other, as close as possible to each other but not in contact (contact would create a short circuit). Ideally, the gap between the two electrodes should also be occupied by an electrolyte with the highest possible conductivity. Typically, liquid electrolytes have the highest conductivity of any electrolyte class. An interelectrode membrane / ionomer / diaphragm (also known as a “separation membrane”) can also typically be placed between the electrodes to prevent electrode contact and to keep the reactants consumed by each electrode and / or the products produced by each electrode separate from each other.

[0008] In industrial applications, individual electrosynthesis units and electro-hydraulic / gas-based units can typically be “stacked” in electrical series with other individual units, resulting in a “cell stack.” This is usually achieved within a so-called “filter-press” arrangement (also known as a “plate-and-frame” arrangement). In such a configuration, individual units with substantially flat profiles can be stacked between two end plates that are compressed toward each other. This allows the centered, stacked individual units to: (i) form and maintain electrical contact with each other (electrical series), and (ii) be firmly held within the stack, thereby: (iii) forming a single electrosynthesis or electro-hydraulic device, i.e., a filter-press type cell stack. The resulting cell stack is then effectively a single device with product outputs from all the merged units and their combined reactant consumption. In this way, large quantities of reactants and products can be accumulated into a single, external product and / or reaction stream, which is easier to manage than multiple smaller streams. Such a single device, or even a combination of multiple such single devices, can also be referred to as a component within an electrosynthesis or electro-hydraulic “unit” (singular form), although in fact they formally comprise multiple separate electrosynthesis or electro-hydraulic units. For example, such a single device may be described as part of a single electrosynthesis unit or electrical energy unit, although it may formally comprise multiple separate electrosynthesis units or electrical energy units. The term may be used conventionally when referring to an industrial electrosynthesis or electrical energy "unit"; that is, an industrial electrosynthesis unit or electrical energy unit (singular form) may include many separate electrosynthesis units or electrical energy units.

[0009] An engineering system, apparatus, or arrangement that supports, manages, and / or controls such a single external flow of reactants and products, as well as the current flowing through a unit or stack of units, is referred to as a "balance-of-plant," "balance-of-stack," or "balance-of-system."

[0010] Plant ancillary facilities for electrosynthesis units, electro-liquid-gas units, or unit stacks can include significant energy-consuming process engineering elements, thus impacting the overall energy efficiency of the entire system. Furthermore, plant ancillary facilities can be more expensive than the units and unit stacks themselves, making them a crucial economic component of the overall electrosynthesis or electro-energy system. Additionally, plant ancillary facilities may be essential to ensuring the reliable and safe operation of the units / unit stacks and achieving their designated outputs.

[0011] System components that manage the electrical energy entering and leaving the power supply and electrosynthesis units form part of the plant's auxiliary facilities. Because a significant amount of electrical energy is involved in operating the power supply and electrosynthesis units, power management components are necessary to maximize energy efficiency during their operation. Higher energy efficiency results in less energy waste throughout the system, leading to lower operating costs and, in the case of the electrosynthesis unit, lower product costs.

[0012] As discussed herein, an "industrial electrolyzer" includes a type of electrosynthesis unit, or a component of a single electrosynthesis unit, or a stack of multiple individual electrosynthesis units, or a combination of stacks each comprising multiple individual electrosynthesis units, which cumulatively require a power input of 50 kW or more and use electrical energy in the form of direct current (DC) to electrochemically drive a non-spontaneous chemical reaction present in a single unit, causing the chemical bonds to break down. The word "lysis" means separation or breakup, so electrolysis means "through electrical breakdown." An "industrial electrolyzer" may also typically include plant auxiliary facilities that support, manage, and / or control the units present. A non-limiting example of an industrial electrolyzer is a water electrolyzer with a power of 50 kW or more that splits water into hydrogen and oxygen. Two types of water electrolyzers are widely used in industry: alkaline electrolyzers and polymer electrolyte membrane (PEM) electrolyzers.

[0013] Like other electrosynthetic units, industrial electrolyzers typically consist of multiple electrolysis units "stacked" together in one or more filter press-type "unit stacks," which are maintained and controlled by surrounding "plant auxiliary" engineering systems. The power supply providing power to the unit stacks of the industrial electrolyzer is often a critical component of the plant auxiliary facilities. The voltage, current, and power range generated by the power supply must generally be compatible with the voltage, current, and power inputs required by the industrial electrolyzer unit stack from the beginning to the end of its lifespan.

[0014] For the reasons given above, it is necessary to optimize or improve the energy efficiency of power supplies used for industrial electrolytic cell unit stacks.

[0015] As described herein, an "industrial power supply" is a rectifier and associated components, wherein the industrial power supply is designed to convert alternating current (AC) (e.g., from the power grid) into direct current (DC) in a static industrial environment. Preferably, but not exclusively, the industrial power supply has a power output of 50 kW or greater. Some non-limiting examples of industrial power supplies are provided in Table 1. It should be understood that those listed in Table 1 are purely illustrative and not exhaustive. Other examples of industrial power supplies not listed in Table 1 may exist. Table 1: Examples of commercially available industrial power supplies as of November 2023.

[0016] Commercially available industrial power supplies are typically configured to operate over a relatively wide range of voltage, current, and power output, which is useful in many industrial applications. This allows for maximum manufacturing volume, thus reducing their cost. Industrial power supplies can also be referred to as power “converters” because they may include one or more conversion stages. For example, some industrial rectifiers may have only a single AC-to-DC conversion stage. These converters typically have a relatively small output voltage range (e.g., 540 V to 850 V at 0 A to 300 A). Other industrial rectifiers may have both AC-to-DC and DC-to-DC conversion stages. These converters typically have a larger output voltage range (e.g., 0 V to 1000 V at 0 A to 300 A). Industrial converters can be categorized into two types: single-stage and multi-stage. Single-stage converters are traditionally six-pulse rectifier configurations with limited boost capabilities. Multi-stage converters are traditionally six-pulse rectifier configurations with both a rectifier stage and a DC-to-DC conversion stage. Single-stage converters may have a smaller output voltage range that depends on the input mains voltage. For example, the ABB ACS880 converter has an output voltage range of 540 V to 860 V with a standard input of 400 V, while the Siemens 6SL3300 converter has an output voltage range of 540 V to 780 V with a standard input of 400 V. However, multi-stage converters typically have a wide output voltage range. For instance, both the RT22 module (supplied by Rectifier Technologies, https: / / www.rectifiertechnologies.com / ) and the CHARX module (supplied by Phoenix Contact, https: / / www.phoenixcontact.com / ) have an output voltage range of 0 V to 1000 V.

[0017] Commercially available industrial power supplies are generally designed to operate over a relatively wide range of voltage, current, and power outputs. However, they typically cannot achieve the highest possible peak energy efficiency at the specific voltage, current, and power inputs required for an industrial electrolyzer unit stack, at least when using standard transformers and switchgear. This can reduce the overall energy efficiency of the entire industrial electrolyzer system, including the power supply. While custom-made, non-standard transformers can be designed to align the highest possible peak energy efficiency with the unit stack, this increases costs due to the low production volume of such transformers. Non-standard or overrated switchgear and other auxiliary equipment may also be required.

[0018] Alternatively, industrial power supplies can be custom-designed to precisely limit the voltage, current, and power ranges to the requirements of industrial electrolyzers. Such power supplies can achieve the highest possible energy efficiency when powering industrial electrolyzers (eliminating the need for non-standard transformers and switching equipment). However, such custom engineering typically limits the industrial applicability of industrial power supplies and restricts their production volume. Because sunk development costs must be amortized over smaller production runs, the resulting low production volume can often significantly increase the cost of the power supply.

[0019] Therefore, when selecting a power source for industrial electrolyzers, trade-offs involving energy efficiency and / or cost may be unavoidable. New methods are needed to avoid this dilemma.

[0020] Industrial power supplies can be air-cooled or liquid-cooled. Liquid cooling is generally more efficient than air cooling in industrial power supplies because liquid water has a specific heat of approximately 4,200 J / (kg℃), higher than air's specific heat of 1,005 J / (kg℃). Liquid cooling can be more advantageous than air cooling in industrial power supplies. For example, liquid cooling removes heat from the equipment more efficiently, allowing it to operate at higher loads and generate more heat. Furthermore, the absence of a fan for cooling purposes reduces audible noise, and the need for regular maintenance is reduced because air filters do not require replacement. Converters can be designed to prevent dust ingress, meaning internal components are not exposed to dirt and dust. This can potentially increase the power supply's lifespan, especially when operating in harsh environments. Furthermore, heat recovery systems can be used to recover heat, which is advantageous in some industries and can reduce substation air conditioning costs. Therefore, an increasing number of industrial power supplies are liquid-cooled.

[0021] In liquid-cooled applications, the substrate or base structure (of a liquid-cooled system heated by the internal components of the power supply) is typically maintained at a stable temperature by allowing a cooling fluid to pass through, surround, or circulate around it. The coolant can be water, or a mixture of water and another fluid, such as a 50% water, 50% glycol mixture. In liquid-cooled industrial power supplies, the substrate or base structure is typically kept below the maximum coolant operating temperature (depending on the manufacturer's ratings or specifications), below 60°C, below 59°C, below 58°C, below 57°C, below 56°C, below 55°C, below 54°C, below 53°C, below 52°C, below 51°C, or below 50°C, for example, at approximately 45°C. In other words, liquid cooling systems can be designed to remove heat at temperatures below 60°C, 59°C, 58°C, 57°C, 56°C, 55°C, 54°C, 53°C, 52°C, 51°C, or 50°C.

[0022] During operation, industrial electrolyzer cell stacks typically generate a considerable amount of heat that must be removed. These stacks must generally be maintained continuously at an operating temperature of 60°C or higher, for example, around 80°C to 90°C. That is, the heat generated by such stacks must typically be removed at 60°C or higher. Liquid cooling is commonly used to cool industrial electrolyzers and maintain them at an operating temperature of 60°C or higher.

[0023] Therefore, the temperature characteristics of liquid cooling required in industrial electrolyzers can differ from those required in industrial power supplies. Consequently, two separate cooling systems are needed. The presence of two cooling systems may reduce overall energy efficiency and increase the cost of the entire industrial electrolyzer system (including the power supply). Alternative methods are needed to improve the energy efficiency of the entire industrial electrolyzer system (including the power supply) and enhance the cost-effectiveness of the industrial electrolyzer power supply.

[0024] Any discussion of prior art throughout the specification should never be construed as an admission that such prior art is widely known or forms part of common knowledge in the art. Summary of the Invention

[0025] This summary is provided to introduce, in a simplified form, a series of concepts further described below in the detailed description. This summary is not intended to identify all the key or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter.

[0026] The inventors have surprisingly discovered that the aforementioned challenges can be addressed and significantly improved by using traction inverters (including, but not limited to, automotive traction inverters) to power industrial electrolyzers. The traction inverter can be reversed in its operating direction to power the industrial electrolyzer, wherein the cell stack of the industrial electrolyzer has been configured to substantially match the voltage, current, and power range generated by the traction inverter. In other words, it has been surprisingly found that if the cell stack of the industrial electrolyzer can be and is configured to substantially match the voltage, current, and power range generated by the traction inverter when it operates in the opposite direction, the traction inverter (including automotive traction inverters) avoids the previously described trade-offs in energy efficiency and / or cost associated with the operation of industrial electrolyzers.

[0027] As discussed herein, a "traction inverter" is a device and associated components with power output that, during normal operation, converts direct current (DC) (e.g., from a battery) into alternating current (AC) (e.g., for a motor) within a non-stationary moving vehicle such as a car, airplane, or similar transport. Preferably, but not exclusively, the traction inverter has a power output of 50 kW or greater. Preferably, but not exclusively, the power output of the traction inverter is intended or designed to propel the movement of a non-stationary moving vehicle. A "vehicle traction inverter" as discussed herein is a traction inverter specifically intended or designed to power the electric motor that propels an electric vehicle (EV).

[0028] Traction inverters are similar to conventional inverters, such as solar inverters, which convert DC power to AC power during normal operation. However, traction inverters differ from conventional inverters in that conventional inverters are designed for use in stationary, fixed locations. Deploying inverters designed for mobile applications in stationary, fixed applications is typically unusual and counterintuitive, as it would significantly exceed design parameters. However, the inventors were surprised to find that such unexpected applications could solve or significantly improve these problems.

[0029] According to a first aspect, the present invention provides a system for supplying power to an electrosynthesis unit, the system comprising: an electrosynthesis unit; and a traction inverter electrically connected to the electrosynthesis unit, the traction inverter comprising: a control system, wherein the control system is configured to operate the traction inverter in reverse such that alternating current (AC) input to the traction inverter is converted into direct current (DC) output from the traction inverter, thereby supplying power to the electrosynthesis unit.

[0030] Preferred, but not exclusively, the electrosynthesis unit is an industrial electrolytic cell.

[0031] Preferred, but not exclusively, the traction inverter is a vehicle traction inverter.

[0032] Preferably, but not exclusively, the traction inverter includes a liquid cooling system with a coolant.

[0033] In some preferred embodiments, the liquid cooling system and coolant are shared by both the traction inverter and the electrosynthesis unit. In other preferred embodiments, the coolant is in fluid communication with both the traction inverter and the electrosynthesis unit.

[0034] During operation, the coolant preferably has a coolant temperature falling within a range, the maximum value of which (i.e., the highest coolant temperature) is greater than or equal to 50 °C, greater than or equal to 51 °C, greater than or equal to 52 °C, greater than or equal to 53 °C, greater than or equal to 54 °C, greater than or equal to 55 °C, greater than or equal to 56 °C, greater than or equal to 57 °C, greater than or equal to 58 °C, or greater than or equal to 59 °C, or greater than or equal to 60 °C.

[0035] During operation, the system preferably has a power density of 5 kW / L or higher, 6 kW / L or higher, 7 kW / L or higher, 8 kW / L or higher, 9 kW / L or higher, 10 kW / L or higher, 12 kW / L or higher, 14 kW / L or higher, or 18 kW / L or higher.

[0036] During operation, the system preferably has a specific power of 5 kW / kg or greater than or equal to 6 kW / kg, 7 kW / kg or greater than or equal to 7 kW / kg, 8 kW / kg or greater than or equal to 8 kW / kg, 9 kW / kg or greater than or equal to 9 kW / kg, 10 kW / kg or greater than or equal to 12 kW / kg, 14 kW / kg or greater than or equal to 18 kW / kg.

[0037] Preferably, the maximum coolant temperature can be greater than or equal to 60 °C, greater than or equal to 59 °C, greater than or equal to 58 °C, greater than or equal to 57 °C, greater than or equal to 56 °C, greater than or equal to 55 °C, greater than or equal to 54 °C, greater than or equal to 53 °C, greater than or equal to 52 °C, greater than or equal to 51 °C, or greater than or equal to 50 °C. Preferably, the traction inverter can have a power density greater than or equal to 5 kW / L, greater than or equal to 6 kW / L, greater than or equal to 7 kW / L, greater than or equal to 8 kW / L, greater than or equal to 9 kW / L, greater than or equal to 10 kW / L, greater than or equal to 12 kW / L, greater than or equal to 14 kW / L, or greater than or equal to 18 kW / L. Preferably, the traction inverter may have a specific power of 5 kW / kg or higher, 6 kW / kg or higher, 7 kW / kg or higher, 8 kW / kg or higher, 9 kW / kg or higher, 10 kW / kg or higher, 12 kW / kg or higher, 14 kW / kg or higher, or 18 kW / kg or higher.

[0038] The control system of the traction inverter can be adjusted from the original configuration to operate the traction inverter in reverse to supply power to the electrosynthesis unit. Alternatively, the control system can be replaced with an alternative control system with a different configuration to operate the traction inverter in reverse to supply power to the electrosynthesis unit.

[0039] The system preferably also includes interface hardware. The interface hardware can be adapted from the original configuration to enable connection to the electrosynthesis unit, or the interface hardware can be replaced with alternative interface hardware with an alternative configuration to enable connection to the electrosynthesis unit.

[0040] The system preferably also includes a pre-charging circuit to provide power to the electrosynthesis unit. The pre-charging circuit can be adjusted from the original configuration to provide power to the electrosynthesis unit, or the pre-charging circuit can be replaced with an alternative pre-charging circuit with an alternative configuration to provide power to the electrosynthesis unit.

[0041] In some implementations, the control system of the traction inverter is adjusted or replaced to operate the traction inverter in reverse to supply power to the electrosynthesis unit, and the interface hardware of the traction inverter is adjusted or replaced to enable connection to the electrosynthesis unit; and the pre-charge circuit of the traction inverter is adjusted or replaced to supply power to the electrosynthesis unit.

[0042] The control system can be adjusted to detect whether the AC input to the traction inverter has a three-phase voltage waveform, and if the AC input to the traction inverter has a three-phase voltage waveform, convert the three-phase voltage waveform into DC output from the traction inverter.

[0043] In some implementations, the pre-charge circuit charges the load voltage of the electrosynthesis unit to the DC bus capacitor voltage in the traction inverter to prevent large inrush currents during system startup.

[0044] According to a second aspect, the present invention provides a traction inverter electrically connected to an electrosynthesis unit, the traction inverter comprising: a control system, wherein the control system is configured to operate the traction inverter in reverse such that alternating current (AC) input to the traction inverter is converted into direct current (DC) output from the traction inverter, thereby supplying power to the electrosynthesis unit.

[0045] According to a third aspect, the present invention provides a traction inverter for use in the system of the first aspect.

[0046] According to a fourth aspect, the present invention provides a traction inverter connected to an industrial electrolyzer, the traction inverter comprising: a control system configured to operate the traction inverter in reverse such that alternating current (AC) is converted into direct current (DC) to supply power to the industrial electrolyzer; wherein the traction inverter includes a liquid cooling system; wherein a maximum coolant temperature is greater than or equal to 50 °C; wherein the power density of the traction inverter is greater than or equal to 5 kW / L; wherein the traction inverter has a specific power greater than or equal to 5 kW / kg; wherein the control system of the traction inverter is adjusted or replaced to operate the traction inverter in reverse to supply power to the industrial electrolyzer; and wherein the interface hardware of the traction inverter is adjusted or replaced to enable connection to the electrolyzer; and / or wherein a pre-charge circuit of the traction inverter is adjusted or replaced to supply power to the industrial electrolyzer. The maximum coolant temperature is preferably greater than or equal to 60 °C.

[0047] According to a fifth aspect, the present invention provides a traction inverter connected to an industrial electrolytic cell, the traction inverter comprising: a control system, wherein the control system is configured to operate the traction inverter in reverse such that alternating current (AC) is converted into direct current (DC) to supply power to the industrial electrolytic cell, wherein the traction inverter includes a liquid cooling system, wherein a maximum coolant temperature is greater than or equal to 60 °C, wherein the power density of the traction inverter is greater than or equal to 18 kW / L, and wherein the traction inverter has a power density greater than or equal to 18 kW / L. The specific power is kW / kg, wherein the control system of the traction inverter is adjusted or replaced to operate the traction inverter in reverse to supply power to the industrial electrolytic cell, and / or wherein the interface hardware of the traction inverter is adjusted or replaced to enable connection to the electrolytic cell; and / or wherein the pre-charge circuit of the traction inverter is adjusted or replaced to supply power to the industrial electrolytic cell, wherein the control system is replaced to a control system that detects the input three-phase voltage waveform and converts it into a controllable DC output, and / or wherein the pre-charge circuit is replaced to charge the load voltage of the industrial electrolytic cell to the DC bus capacitor voltage in the traction inverter to prevent large inrush current during startup.

[0048] According to a sixth aspect, the present invention provides a method for supplying power to an electrosynthetic unit, the electrosynthetic unit comprising: at least one electrode requiring a direct current (DC) supply for operation of the electrosynthetic unit; and a traction inverter electrically connected to the electrosynthetic unit, the method comprising: reversing the operation of the traction inverter such that an alternating current (AC) input to the traction inverter is converted into direct current (DC) output from the traction inverter and supplied to the at least one electrode.

[0049] Preferably, the electrosynthesis unit is an industrial electrolytic cell.

[0050] Preferably, the traction inverter includes a control system, and the control system is configured to operate the traction inverter in reverse.

[0051] The method preferably includes configuring the electrosynthesis unit and / or at least one electrode to require a voltage and / or current and / or power input range substantially similar to the voltage and / or current and / or power output range of the traction inverter.

[0052] The preferred traction inverter is a vehicle traction inverter.

[0053] Multiple electrosynthesis units can be set in one or more unit stacks.

[0054] Configuring at least one electrode preferably involves configuring the size of at least one electrode to provide a selected range of current. Configuring a single cell in a plurality of electrosynthesizing units preferably includes configuring the number of single cells in one or more cell stacks to provide a selected range of voltage. Configuring a single cell in a plurality of electrosynthesizing units preferably includes optimizing one or more cell stacks to avoid or minimize the occurrence or effect of shunt or bypass currents thereby providing a selected range of power input.

[0055] The control system preferably enables constant reverse operation of the traction inverter. The method preferably involves detecting whether the alternating current (AC) input to the traction inverter has a three-phase voltage waveform via the control system, and if so, converting the three-phase voltage waveform into direct current (DC) output from the traction inverter. The method may also include a pre-charge circuit for charging the load voltage of the electrosynthetic unit to the DC bus capacitor voltage in the traction inverter to prevent large inrush currents during the start-up of the electrosynthetic unit.

[0056] According to the seventh aspect, the present invention provides a system, traction inverter or method of the foregoing aspects, wherein the traction inverter has a power output of greater than or equal to 50 kW.

[0057] According to the eighth aspect, the present invention provides a system, traction inverter or method of the foregoing aspects, wherein the traction inverter is intended or designed to propel a non-stationary moving vehicle.

[0058] Traction inverters can be configured to operate in reverse. That is, traction inverters can be configured to convert alternating current (AC) into direct current (DC). For example, during regenerative braking in an electric vehicle, a vehicle traction inverter can convert AC power (e.g., from the rotating electric vehicle motor) into DC power (e.g., stored in the electric vehicle battery).

[0059] Traction inverters can be distinguished from industrial power supplies in several important aspects, as described below.

[0060] First, traction inverters are specifically designed to convert direct current (DC) to alternating current (AC) in non-stationary vehicle environments. The nature of mobile applications and the associated issues, such as limited space and weight, mean that the requirement to minimize space and weight (where space and weight are valuable) means that the efficiency, weight, and size of traction drive inverters have always been key considerations in traction inverter technology design. In contrast, due to the stationary nature of typical use cases for industrial power supplies, weight and volume are less critical. Therefore, second, traction inverters can often be much more compact than industrial power supplies, a critical requirement in non-stationary vehicle environments but far less important in stationary industrial environments. For example, traction inverters can typically exhibit high power densities of 5 kW / L or higher, 6 kW / L or higher, 7 kW / L or higher, 8 kW / L or higher, 9 kW / L or higher, 10 kW / L or higher, 12 kW / L or higher, 14 kW / L or higher, or 18 kW / L or higher. They can also exhibit high specific power of 6 kW / kg or higher, 6 kW / kg or higher, 7 kW / kg or higher, 8 kW / kg or higher, 9 kW / kg or higher, 10 kW / kg or higher, 12 kW / kg or higher, 14 kW / kg or higher, or 18 kW / kg or higher. Third, due to their compact design, traction inverters typically must be liquid-cooled, and the temperature of the liquid coolant is significantly higher than that of the industrial power supply during operation. For example, traction inverters can typically have a maximum coolant operating temperature greater than or equal to 60 °C, such as approximately 70 °C to 90 °C. Fourth, traction inverters can typically be configured to output a narrower range of voltage, current, and power during continuous operation than industrial power supplies, because traction inverters are designed for very specific mobility applications, such as powering particular electric vehicles that may only require high power for short periods during vehicle acceleration. This narrower range provides higher peak energy efficiency operation compared to the wider range typically achievable with industrial power supplies. Fifth, traction inverters can typically utilize high-performance electronic components, such as insulated-gate bipolar transistors (IGBTs) and / or silicon carbide (SiC) switches; traction inverters based on such components are readily commercially available. Sixth, such components enable higher energy efficiency compared to older, less complex components. Seventh, therefore, due to the booming electric vehicle market, the supply chain for components used in the efficient design of traction inverters is more developed than that of industrial power supplies. Eighth, traction inverters have a long history of utilizing high-performance electronic components, such as IGBTs and SiC switches.The operation of these components and their efficient design has been thoroughly developed into a mature technology, now well-documented and highly reliable. In contrast, the optimization requirements for efficient and compact industrial power supply designs are a recent trend with a shorter history. This shorter history, compared to traction drives, suggests that the amount of accurate reliability data may be less abundant. Ninth, traction inverters, such as, but not limited to, automotive traction inverters, can be manufactured in much larger batches than industrial power supplies. For example, hundreds of thousands of automotive traction inverters can be manufactured annually, which is not uncommon in the automotive industry. Such high-volume manufacturing can result in lower costs / prices per unit compared to the smaller-scale manufacturing of industrial power supplies.

[0061] The inventors have surprisingly discovered that: (a) if the cell stacks of an industrial electrolyzer can be designed and configured such that their voltage, current and power requirements substantially match the voltage, current and power requirements of a traction inverter in reverse operation, and (b) if the traction inverter can be adjusted or modified to connect to and control the cell stacks of an industrial electrolyzer configured in this way, then this can relatively increase overall energy efficiency and reduce the overall cost of the entire industrial electrolyzer system relative to the use of an industrial power supply.

[0062] Step (a) above may involve: - Configure the size of the electrodes in the cell stack to provide a specific range of current. - Configure the number of cells in the cell stack to provide a specific range of voltages, and / or - Optimize the size of the electrodes, the number of cells, and their configuration in the cell stack to avoid or minimize the occurrence or impact of "shunt" current (also known as "bypass" current) to provide a specific range of power input.

[0063] Step (b) may involve: - Adjust or replace the control system of the traction inverter so that the traction inverter can provide DC power to operate the industrial electrolytic cell. - Adjust or replace the interface hardware of the traction inverter to enable the traction inverter to provide power to operate the industrial electrolytic cell. - Adjust or replace the control system to detect the input three-phase voltage waveform and convert it into a controllable DC output, and / or - Adjust or replace the pre-charge circuit of the traction inverter to power the industrial electrolyzer. Preferably, the pre-charge circuit is adjusted or replaced to charge the load voltage of the industrial electrolyzer to the DC bus capacitor voltage in the traction inverter, thereby preventing large inrush currents during startup. How to use

[0064] A method for supplying power to an industrial electrolytic cell with reverse-operation traction inverters (including automotive traction inverters) is also provided, the method comprising: (1) Configure individual cells and their electrodes in a cell stack of an industrial electrolyzer to provide voltage, current, and power input ranges that are substantially similar to those generated by a traction inverter. This may involve configuring: the size of the electrodes in the cell stack to provide a specific range of current; the number of cells in the cell stack to provide a specific range of voltage; and / or optimizing the size of the electrodes, the number of cells, and their configuration in the cell stack to avoid or minimize the occurrence or effect of “shunt” currents (also known as “bypass” currents) to provide a specific range of power input; (2) Adjusting or replacing the control system and / or interface hardware and / or other components of the traction inverter. For example, the control system can be modified to enable constant reverse operation of the traction inverter. In another example, the interface hardware of the traction inverter can be changed. In yet another example, a new control system or interface can be retrofitted. Connecting the traction inverter to an industrial electrolyzer; and (3) The current is transmitted from the traction inverter to the industrial electrolytic cell. Additional aspects

[0065] Methods for simplifying step (1) above are also provided, which involve: employing industrial electrolyzer cell stacks capable of achieving high energy efficiency, including but not limited to the cell stacks described in International Patent Publications WO2022056603, WO2022056604, WO2022056605 and WO2022056606, which are incorporated herein by reference. This can improve the overall energy efficiency of the entire industrial electrolyzer system (including the power supply); and using techniques including but not limited to those described in International Patent Publications WO 2022056603, WO 2022056604, WO 2022056605 and WO 2022056606 to avoid “shunting” currents (also known as “bypass” currents) in the industrial electrolyzer cell stacks, which are incorporated herein by reference.

[0066] In the context of this invention, the words “comprise” and “comprising” should be interpreted as inclusive rather than exclusive, that is, in the sense of “including but not limited to”.

[0067] The present invention will be described with reference to at least one of the technical problems described or attached to the background art. The object of the present invention is to solve or improve at least one of the technical problems, and this can produce one or more advantageous effects as defined in this specification and described in detail with reference to preferred embodiments of the invention. Attached Figure Description

[0068] Figure 1 An example implementation is schematically depicted, wherein the unit stack of the traction inverter and the industrial electrolyzer has a separate liquid cooling circuit.

[0069] Figure 2 An example implementation is schematically depicted, in which the unit stack of the traction inverter and the industrial electrolyzer has a common liquid cooling circuit.

[0070] Figure 3 An example method for applying an embodiment of the present invention is illustrated schematically. Detailed Implementation

[0071] Preferred embodiments of the invention will now be described with reference to the accompanying drawings and non-limiting examples.

[0072] In this document, the term "user" refers to a person who files or wishes to file a patent application. The term "agent" refers to a suitably skilled professional capable of drafting and filing a patent application. In most cases, an agent is a patent attorney, a patent law firm, or a lawyer specializing in patent examination. definition

[0073] As discussed herein, an "electric energy unit" is an electrochemical unit that continuously or intermittently generates electricity for use outside the unit over an indeterminate period of time. During operation, an electrical energy unit may require a constant external supply of reactants. The products of the electrochemical reactions may also be continuously removed from such a unit during operation. An electrical energy unit can be a liquid-gas unit. An example of an electrical energy unit is a hydrogen-oxygen fuel cell. This example is also a liquid-gas unit.

[0074] As discussed herein, an “electrosynthesis unit” is an electrochemical unit that continuously or intermittently produces one or more chemical substances for use outside the unit over an indeterminate period of time. The chemical substances can be in gaseous, liquid, or solid form. Like an electrical energy unit, an electrosynthesis unit may require a constant supply of reactants and a constant removal of products during operation. Typically, an electrosynthesis unit may also require a constant input of electrical energy during operation. An electrosynthesis unit can be a liquid-gas unit. An example of an electrosynthesis unit is a water electrolysis unit. This example is also a liquid-gas unit.

[0075] As discussed herein, electrical energy units and electrosynthesis units differ from other types of electrochemical units, such as batteries and sensors, because they do not incorporate all or some of the reactants required for operation into the unit body, nor do they incorporate all or some of the products generated during operation. Instead, these can be continuously introduced into or removed from the unit body during operation. For example, an electrical energy unit differs from a primary unit in that the primary unit stores its reactants and products within its own body. Unlike a battery, an electrical energy unit does not store chemical or electrical energy within it. Similarly, while some electrochemical sensors may consume reactants and generate products in limited quantities during sensing operation, all or some of these are stored within the unit body itself.

[0076] As used herein, the term "unit" can refer to a single unit in the singular or a collection of single units in the plural. For example, an electrical energy or electrosynthesis "unit" can refer to a single, individual electrical energy unit or electrosynthesis unit, or it can refer to multiple individual electrical energy units or electrosynthesis units combined into a single device.

[0077] As discussed herein, an "industrial electrolyzer" is defined as comprising one type of electrosynthesis unit, or a component of individual electrosynthesis units, or a stack of multiple individual electrosynthesis units, or a combination of stacks each comprising multiple individual electrosynthesis units, with a cumulative power greater than or equal to 50 kW, employing electrical energy in the form of direct current (DC) to electrochemically drive a non-spontaneous chemical reaction present within a single electrosynthesis unit, resulting in the separation of chemical bonds. The word "breakdown" means separation or rupture, so electrolysis means "by electrical breakdown." An "industrial electrolyzer" may also typically include plant auxiliary equipment that supports, manages, and / or controls the presence of the unit. An example of an industrial electrolyzer is a water electrolyzer with a power greater than or equal to 50 kW, which splits water into hydrogen and oxygen. Two types of water electrolyzers are widely used in industry: alkaline electrolyzers and polymer electrolyte membrane (PEM) electrolyzers.

[0078] As discussed herein, an "industrial power supply" is defined as a rectifier and associated components having power output, wherein the industrial power supply is designed to preferably convert alternating current (AC) into direct current (DC) in a static industrial environment. Preferably, but not exclusively, the industrial power supply has a power output of 50 kW or more.

[0079] As discussed herein, a "traction inverter" is defined as a device and associated components having a power output configured to convert direct current (DC) into alternating current (AC) within a non-stationary moving vehicle such as a car, airplane, or similar transport. Preferably, but not exclusively, the traction inverter has a power output of 50 kW or greater. Preferably, but not exclusively, the power output of the traction inverter is intended or designed to propel the movement of a non-stationary moving vehicle. A "vehicle traction inverter" is defined herein as a traction inverter specifically intended or designed to power an electric motor that propels an electric vehicle (EV).

[0080] As used herein, the terms “maximum coolant temperature” or “maximum coolant operating temperature” are defined as the highest temperature that a liquid coolant can reach during continuous or sustained use of a liquid-cooled device, according to the manufacturer’s ratings or specifications or in practical applications. “Coolant” is defined as a coolant liquid, which can be water, a mixture of water and another fluid, such as a 50% water, 50% ethylene glycol mixture, or any type of coolant liquid.

[0081] The “power density” of a power source (including but not limited to industrial power sources, traction inverters, or vehicle traction inverters) is defined in this document as the power per unit volume of the power source (which may also be referred to as “volume power density”).

[0082] The "specific power" of a power source (including but not limited to industrial power sources, traction inverters, or vehicle traction inverters) is defined in this document as the power per unit mass of the power source (which may also be referred to as "weight power density"). Example embodiments of the present invention

[0083] The inventors have surprisingly discovered that powering industrial electrolyzers with a commercially available traction inverter operating in reverse can produce higher energy efficiency and lower overall system cost compared to using commercially available industrial power supplies, provided that: (a) the cell stacks of the industrial electrolyzers can be designed and configured such that their voltage, current, and power requirements substantially match but never exceed the voltage, current, and power requirements of the traction inverter in reverse operation; and (b) the traction inverter can be adjusted or modified to connect to and control the cell stacks of the industrial electrolyzers configured in this way.

[0084] The difference between traction inverters and industrial power supplies is that traction inverters are specifically designed to convert direct current (DC) to alternating current (AC) in non-stationary vehicle environments, while industrial power supplies are designed to convert alternating current (AC) to direct current (DC) in stationary non-vehicle environments.

[0085] Traction inverters can be configured to operate in reverse; that is, to convert alternating current (AC) to direct current (DC). For example, during regenerative braking in an electric vehicle, a vehicle traction inverter can convert AC power (e.g., from the rotating electric vehicle motor) into DC power (e.g., stored in the electric vehicle battery). Regenerative braking is essentially an energy recovery mechanism. During regenerative braking, the kinetic energy of a moving vehicle or object is converted into a form that can be used immediately or stored until needed. In this mechanism, the power traction motor uses the vehicle's momentum to recover energy that would otherwise be dissipated as heat to the brake discs. Conversely, in conventional braking systems, excess kinetic energy is converted into unwanted and wasted heat due to friction in the brakes. For rheostatic brakes, kinetic energy is recovered by using an electric motor as a generator, but dissipated as heat in the resistor. This is designed to improve the overall energy efficiency of the vehicle. A reverse-operated traction inverter refers to converting a three-phase power input to a DC output. A new control system may be required to facilitate the reverse conversion. When a load (in the case of this invention, an industrial electrolyzer) is connected to the DC output terminal of the converter, the pre-charge circuit can be reused to slowly increase the current.

[0086] When operating in traction inverter mode, the control system can use a motor control algorithm to control the inverter to generate a controllable three-phase voltage for optimal control of the traction motor. When the traction inverter operates in reverse, this control system can be replaced with a system that detects the input three-phase voltage waveform and converts it into a controllable DC output.

[0087] The capacitors inside the traction inverter may need to be slowly charged to the battery before connection to prevent large currents that could potentially damage the vehicle's battery or capacitors. In traction inverter mode, the capacitors can be slowly charged to the battery voltage before outputting current to the motor during startup. When the traction inverter operates in reverse mode, a pre-charge circuit can be activated to provide soft-start capability, slowly charging the load voltage of the industrial electrolyzer to the capacitor voltage. This avoids large in-rush currents during startup.

[0088] For the reasons discussed below, it has been surprisingly found that traction inverters (including automotive traction inverters) avoid the cost trade-offs involving energy efficiency and / or the operation of industrial electrolyzers discussed in the background section.

[0089] Traction inverters are designed for very specific mobile applications. They can typically be configured to output a narrower range of continuous voltage, current, and power than some industrial power supplies, including when the traction inverter is operating in reverse—that is, when converting AC current to DC current. This narrower range provides higher peak energy efficiency operation compared to the wider range typically achievable with industrial power supplies. The inventors have surprisingly discovered that if the cell stacks of an industrial electrolyzer are designed such that their voltage, current, and power requirements substantially match those of the traction inverter when it is operating in reverse, this can increase the relative overall energy efficiency of the entire industrial electrolyzer system, including the power supply.

[0090] Furthermore, because traction inverters can be produced in very large quantities, they are typically readily available commercially at a much lower cost than comparable industrial power supplies. For example, traction inverters used in electric vehicles can be mass-produced in quantities of hundreds of thousands per year, which can far exceed the mass production of any industrial power supply. This feature can reduce the relative total cost of the entire industrial electrolyzer system, including the power supply.

[0091] A traction inverter can be adapted to operate in reverse to convert AC current to DC current. That is, adaptation can involve changes to the control system and / or interface hardware and / or other components of the traction inverter. For example, the control system can be modified to enable constant reverse operation of the traction inverter. In another example, the interface hardware of the traction inverter can be changed. In yet another example, a new control system or interface can be retrofitted.

[0092] Therefore, using a commercially available traction inverter operating in reverse to power an industrial electrolyzer can result in higher energy efficiency and lower overall cost compared to using commercially available industrial power supplies.

[0093] Additionally, using traction inverters (including automotive traction inverters) to power industrial electrolyzers can avoid the aforementioned need for two different cooling systems for the following reasons:

[0094] Traction inverters are typically liquid-cooled. Unlike industrial power supplies, traction inverters can typically operate with coolant temperatures of 60°C or higher, 59°C or higher, 58°C or higher, 57°C or higher, 56°C or higher, 55°C or higher, 54°C or higher, 53°C or higher, 52°C or higher, 51°C or higher, or 50°C or higher, such as from about 70°C to about 90°C, which is typically required in non-stationary mobile applications.

[0095] The maximum coolant temperature required in the industrial electrolyzer (greater than or equal to 60 °C) can be the same as or similar to the maximum coolant temperature of the traction inverter. Both the industrial electrolyzer and the traction inverter can have a single liquid cooling system. Such an arrangement can provide a relative improvement in overall energy efficiency and reduce the cost of the entire industrial electrolyzer system, including the power supply.

[0096] Traction inverters (including automotive traction inverters) may be potentially suitable power systems for industrial electrolyzers for the following reasons:

[0097] Commercially available traction inverters typically utilize high-performance electronic components such as insulated-gate bipolar transistors (IGBTs) and silicon carbide (SiC) switches. Such components enable higher energy efficiencies that were unattainable with older, less sophisticated components. Many electric vehicle owners experience issues such as "range anxiety," meaning that the efficiency, weight, and size of traction drive inverters have always been key considerations in the design of this technology. In contrast, efficiency, weight, and size are less critical for industrial power supplies due to the fixed nature of typical use cases and the fact that previous industrial applications did not require ultra-efficient drives. Therefore, the components used in the efficient designs within traction inverters have a more developed supply chain compared to industrial power supplies.

[0098] Furthermore, traction inverters have a long history of utilizing high-performance electronic components, such as insulated-gate bipolar transistors (IGBTs) and silicon carbide (SiC) switches. Their operation using such components and efficient designs has been thoroughly developed into a mature, well-documented, and highly reliable technology. In contrast, the optimization requirements for efficient and compact industrial power supply designs are a recent trend with a shorter history. This shorter history, compared to traction drives, suggests that the amount of accurate reliability data may be less abundant.

[0099] Traction inverters can be highly compact, which is often required in non-stationary mobile applications. For example, traction inverters can be much more compact than conventional industrial power supplies. Therefore, using traction inverters to power industrial electrolyzers can provide a significant reduction in the total footprint of the entire industrial electrolyzer system, including the power supply. The compact size and high power density of automotive traction inverters are largely due to the fact that automakers have been trying to reduce drive weight and size to improve vehicle performance and range. Power density is not important in stationary industrial applications, so industrial power supplies are generally not optimized in this regard.

[0100] Therefore, the present invention provides a reverse-operated traction inverter to provide power for operating industrial electrolyzers.

[0101] Preferred, but not exclusively, the traction inverter is a vehicle traction inverter.

[0102] Preferably, but not exclusively, the traction inverter has a liquid cooling system, and the maximum coolant temperature during operation is greater than or equal to 60 °C. In other examples, the maximum coolant temperature is greater than or equal to 59 °C, greater than or equal to 58 °C, greater than or equal to 57 °C, greater than or equal to 56 °C, greater than or equal to 55 °C, greater than or equal to 54 °C, greater than or equal to 53 °C, greater than or equal to 52 °C, greater than or equal to 51 °C, or greater than or equal to 50 °C.

[0103] A traction inverter operating in reverse is provided to power an industrial electrolyzer, wherein the traction inverter and the industrial electrolyzer share a common liquid cooling system, and the maximum coolant temperature is greater than or equal to 60 °C. In other examples, the maximum coolant temperature is greater than or equal to 59 °C, 58 °C, 57 °C, 56 °C, 55 °C, 54 °C, 53 °C, 52 °C, 51 °C, or 50 °C. Alternatively, the liquid coolant in the liquid cooling system can be in fluid communication with both the traction inverter and the industrial electrolyzer.

[0104] On the other hand, the traction inverter has a power density of 5 kW / L or higher. In other examples, the traction inverter has a power density of 6 kW / L or higher, 7 kW / L or higher, 8 kW / L or higher, 9 kW / L or higher, 10 kW / L or higher, 12 kW / L or higher, 14 kW / L or higher, or 18 kW / L or higher.

[0105] On the other hand, the traction inverter has a specific power of 5 kW / kg or greater. In other examples, the traction inverter has a specific power of 6 kW / kg or greater, 7 kW / kg or greater, 8 kW / kg or greater, 9 kW / kg or greater, 10 kW / kg or greater, 12 kW / kg or greater, 14 kW / kg or greater, or 18 kW / kg or greater.

[0106] On the other hand, the control system of the traction inverter is adjusted or replaced so that the traction inverter can supply power to the industrial electrolytic cell.

[0107] On the other hand, the interface hardware of the traction inverter was adjusted or replaced so that the traction inverter could power the industrial electrolytic cell.

[0108] Preferably, the control system of the traction inverter is adjusted or replaced so that the traction inverter can provide power to operate the industrial electrolytic cell, wherein the interface hardware of the traction inverter is adjusted or replaced so that the traction inverter can provide power to operate the industrial electrolytic cell.

[0109] On the other hand, a traction inverter is provided, wherein the pre-charge circuit of the traction inverter is adjusted to supply power to the industrial electrolytic cell.

[0110] Preferably, the pre-charging circuit of the traction inverter is replaced to power the industrial electrolytic cell.

[0111] Preferably, but not exclusively, the control system of the traction inverter is adjusted or replaced to power the industrial electrolytic cell, and the interface hardware of the traction inverter is adjusted or replaced to be able to connect to the electrolytic cell; and wherein the pre-charging circuit of the traction inverter is adjusted or replaced to power the industrial electrolytic cell.

[0112] On the other hand, a traction inverter is provided in which the control system is replaced by a control system that detects the input three-phase voltage waveforms and converts them into controllable DC outputs.

[0113] Preferably, the pre-charge circuit is replaced to charge the load voltage of the industrial electrolyzer to the DC bus capacitor voltage in the traction inverter to prevent large inrush currents during startup.

[0114] Therefore, the inventors have surprisingly discovered that: (a) if the cell stacks of an industrial electrolyzer can be designed and configured such that their voltage, current and power requirements substantially match the voltage, current and power requirements of the traction inverter during reverse operation, and (b) if the traction inverter can be adjusted or modified to connect to and control the cell stacks of an industrial electrolyzer configured in this way, then this can increase the relative overall energy efficiency and reduce the overall cost of the entire industrial electrolyzer system relative to the use of an industrial power supply.

[0115] Step (a) above may involve: - Configure the size of the electrodes in the cell stack to provide a specific range of current. - Configure the number of cells in the cell stack to provide a specific range of voltages, and / or - Optimize the size of the electrodes, the number of cells, and their configuration in the cell stack to avoid or minimize the occurrence or impact of "shunt" current (also known as "bypass" current) to provide a specific range of power input.

[0116] Step (b) may involve: - Adjust or replace the control system of the traction inverter so that the traction inverter can provide power to operate the industrial electrolytic cell. - Adjust or replace the interface hardware of the traction inverter to enable the traction inverter to provide power to operate the industrial electrolytic cell. - Adjust or replace the control system to detect the input three-phase voltage waveform and convert it into a controllable DC output, and / or - Adjust or replace the pre-charge circuit of the traction inverter to power the industrial electrolyzer. Preferably, the pre-charge circuit is adjusted or replaced to charge the load voltage of the industrial electrolyzer to the capacitor voltage in the traction inverter, thereby preventing large inrush currents during startup. How to use

[0117] A method for supplying power to industrial electrolytic cells, including traction inverters (including automotive traction inverters) that include reverse operation, is also provided, the method comprising: (1) Configure individual cells and their electrodes in a cell stack of an industrial electrolyzer to provide voltage, current, and power input ranges that are substantially similar to those of a traction inverter. This may involve configuring: the size of the electrodes in the cell stack to provide a specific range of current; the number of cells in the cell stack to provide a specific range of voltage; and / or optimizing the size of the electrodes, the number of cells, and their configuration in the cell stack to avoid or minimize the occurrence or effect of “shunt” currents (also known as “bypass” currents) to provide a specific range of power input; (2) Adjusting or replacing the control system and / or interface hardware and / or other components of the traction inverter. For example, the control system can be modified to enable constant reverse operation of the traction inverter. In another example, the interface hardware of the traction inverter can be changed. In yet another example, a new control system or interface can be retrofitted. Connecting the traction inverter to an industrial electrolyzer; and (3) The current is transmitted from the traction inverter to the industrial electrolytic cell. Additional aspects

[0118] Methods for simplifying step (1) above are also provided, which involve: employing industrial electrolyzer cell stacks capable of achieving high energy efficiency, including but not limited to the cell stacks described in International Patent Publications WO2022056603, WO2022056604, WO2022056605 and WO2022056606, which are incorporated herein by reference. This can improve the overall energy efficiency of the entire industrial electrolyzer system (including the power supply); and using techniques including but not limited to those described in International Patent Publications WO2022056603, WO2022056604, WO2022056605 and WO2022056606 to avoid “shunting” currents (also known as “bypass” currents) in the industrial electrolyzer cell stacks, which are incorporated herein by reference. Table 2: Example traction inverters as of November 2023. Table 3: Examples of traction inverters used in automobiles (as reported in John Reimers et al., Automotive Traction Inverters: Current Status and Future Trends. IEEE Transactions on Vehicular Technology, 2019, DOI: 10.1109 / TVT.2019.2897899). Other example implementations

[0119] Table 2 provides a non-limiting list of example traction inverters and automotive traction inverters commercially available as of November 2023. It should be understood that the list in Table 2 is purely illustrative and not exhaustive. Other traction inverters not listed in Table 2 may fall within the scope of this invention.

[0120] Table 3 provides a non-limiting list of traction inverters used in electric vehicles and electric hybrid vehicles. It should be understood that the list in Table 3 is purely illustrative and not exhaustive. Other automotive traction inverters not listed in Table 3 may fall within the scope of this invention.

[0121] Figure 1 A schematic diagram of an example implementation is provided. The industrial electrolyzer 100 includes a traction inverter 110 (within its plant auxiliary facilities) connected to a cell stack 111 within the industrial electrolyzer 100. In reverse operation, electrical energy in the form of AC power is delivered along an external cable or bus connection 101 to the AC side (110-AC) of the traction inverter 110, which then converts the AC power into DC power output at its DC side (110-DC). The DC side (110-DC) of the traction inverter 110 is connected to a DC cable or bus 102, which in turn connects to the cell stack 111 of the industrial electrolyzer 100.

[0122] It should be understood that the traction inverter 110 can be any traction inverter, including any traction inverter described herein, or any other traction inverter that falls within the definition of a traction inverter provided herein.

[0123] The traction inverter 110 can be, for example, a traction inverter designed for automobiles (electric vehicles), such as the type manufactured by Eaton Corporation, 1000 Eaton Avenue, Beechwood, Ohio, 44122, USA, which is listed in Table 2 on pages 24-27 of the Eaton eMobility manual (Eaton_eMobility_Interactive Brochure_2-9-23_V9.4 pro_SPFSV.pdf, available from...). https: / / www.eaton.com / content / dam / eaton / products / emobility / eaton-emobility-guide-brochure-emob0001-en.pdf Download (date: February 15, 2023), and the website. https: / / www.eaton.com / us / en-us / catalog / emobility / high- voltage-inverter.html Technical details of the traction inverter are provided. Its peak energy efficiency ranges from 95% to 98%, depending on whether IGBTs or SiC power electronic switches are used. The rated power at peak load is 80 kW to 250 kW, with a maximum output voltage of 800 V and a current of 300 A to 800 A. Eaton traction inverters are also liquid-cooled. The manufacturer outlines that the liquid coolant should be maintained at a temperature up to 70 °C at a flow rate of 10 liters per minute. The power density of the traction inverter is 35 kW / L.

[0124] like Figure 1 As depicted, the traction inverter 110 includes a liquid cooling circuit 120, in which liquid coolant 121 flows in the direction indicated by the arrow (at 121). The liquid cooling circuit 120 passes through a cooling unit 125, which maintains the temperature of the liquid coolant 121. As described above, during operation of the traction inverter 100, the highest coolant temperature of the liquid coolant 121 in the cooling circuit 120 is 70 °C; this is greater than or equal to 60 °C, greater than or equal to 59 °C, greater than or equal to 58 °C, greater than or equal to 57 °C, greater than or equal to 56 °C, greater than or equal to 55 °C, greater than or equal to 54 °C, greater than or equal to 53 °C, greater than or equal to 52 °C, greater than or equal to 51 °C, or greater than or equal to 50 °C. The cooling unit 125 may be, for example, a liquid cooler.

[0125] It should be understood that the industrial electrolyzer 100 and the unit stack 111 can be any type of industrial electrolyzer and unit stack, including alkaline, PEM, solid oxide, or any other type of electrolyzer and associated unit stack.

[0126] The industrial electrolyzer 100 may be an alkaline electrolyzer of the type described in International Patent Publications WO2022056603, WO2022056604, WO2022056605 and WO2022056606, and is manufactured by Hysata Private Limited, 1 Dassey Road, Port Kembra, New South Wales, Australia 2505. The electrolyzer may comprise a unit stack 111. The unit stack 111 may be designed and configured to require an input voltage of 755 V to 775 V and a current of 280 A during operation (over the life of the electrolyzer). These values ​​may be selected to substantially match the aforementioned Eaton traction inverter, as they are slightly lower than the Eaton traction inverter's maximum output voltage of 800 V and current of 300 A. That is, the industrial electrolyzer unit stack 111 may be designed to operate at values ​​close to but not exceeding the maximum values ​​of the traction inverter 100. In this way, the industrial electrolytic cell unit stack 111 can be configured to have a voltage and current range that is substantially similar to the voltage and current range generated by the traction inverter 110.

[0127] This can be achieved by incorporating 500 individual units into a unit stack 111, where each unit is designed and configured to require 1.51 V to 1.55 V during operation (over the lifetime of the electrolyzer). Furthermore, each unit can be configured to utilize 400 cm⁻¹ 2 Electrode area, which means that during operation, at 0.700 A / cm 2 At a fixed current density (over the life of the electrolyzer), each unit requires 280 A of current to pass through it. Since each unit in the unit stack 111 can be electrically connected in series to the next unit in the stack 111, the unit stack 111 may require 280 A of current to pass through it during operation of the industrial electrolyzer 110. Furthermore, since the industrial electrolyzer 100 of the type described in International Patent Publications WO2022056603, WO2022056604, WO2022056605, and WO2022056606 avoids “shunt” current (also known as “bypass” current) in the unit stack 111, the total power required by the industrial electrolyzer unit stack 111 during operation (over the life of the electrolyzer) can be from 211 kW to 217 kW, a simple function of the required voltage and current range.

[0128] In this way, individual cells, individual electrodes, and their configurations in the cell stack 111 of the industrial electrolyzer 100 can be configured to provide voltage, current, and power input ranges substantially similar to those of the traction inverter 110. This can involve configuring: the size of the electrodes in the cell stack to provide a desired range of current; the number of cells in the cell stack to provide a desired range of voltage; and optimizing the size of the electrodes, the number of cells, and their configuration in the cell stack to avoid the occurrence and effects of “shunt” currents (also known as “bypass” currents) to provide a specific range of power input.

[0129] Most alkaline electrolyzer cell stacks allow for shunt currents. Achieving the aforementioned well-defined and narrow power range (over the electrolyzer's lifetime) with electrolyzer cell stacks that allow for shunt currents is far more difficult. This is because shunt currents can be inherently unpredictable and "self-amplifying"; that is, they can unexpectedly alter their patterns within the cell stack and increase significantly in intensity over time, especially, but not only, when they introduce new corrosion mechanisms and pathways within the cell stack. Therefore, avoiding shunt currents significantly simplifies the process of matching the voltage, current, and power requirements of cell stack 111 (over the electrolyzer's lifetime) with the output of the reverse-operated traction inverter 110.

[0130] During operation of the industrial electrolyzer 100, the temperature of the unit stack 111 can be between 75°C and 90°C. The unit stack 111 can be liquid-cooled and includes a liquid cooling circuit 130 in which a liquid coolant 131 flows (in the direction of arrow 131). The liquid cooling circuit can flow through a cooling unit 135, which manages the temperature of the liquid coolant 131 in the liquid cooling circuit 130. When operating at 75°C, the liquid coolant 131 can be maintained at a temperature of 70°C. The cooling unit 135 can be, for example, a liquid cooler.

[0131] In one implementation method (such as) Figure 1 As shown, the traction inverter 110 operating in reverse (i.e., transferring power from the AC side to the DC side) can power the unit stack 111. The traction inverter 110 and the unit stack 111 can have two separate liquid cooling systems, namely a cooling system 120 for the traction inverter 110 and a cooling system 130 for the unit stack 111. During operation, the temperature of the liquid coolant 121 in the traction inverter 110 is as high as 70 °C, and the temperature of the liquid coolant 131 in the unit stack 111 (e.g., operating at 90 °C) is 85 °C.

[0132] In another example implementation, during operation, the coolant temperature within the unit stack 111 may be similar to or the same as the coolant temperature within the traction inverter 110, for example, 70 °C. Figure 2 This scenario is illustrated schematically. An industrial electrolyzer 200 may include a traction inverter 110 operating in reverse, wherein the traction inverter 110 and the unit stack 111 share a common liquid cooling system 140, wherein the maximum coolant temperature of the liquid coolant 141 is 70 °C. That is, the liquid coolant of the liquid cooling system 140 is in fluid communication with both the traction inverter 110 and the unit stack 111. Externally supplied AC power can be delivered to the AC side (110-AC) of the traction inverter 110 operating in reverse via AC cable or bus 101. The traction inverter 110 can output DC power on its DC side (110-DC), which is connected to a DC cable or bus 102, thereby connecting to the unit stack 111. The liquid coolant 141 can flow around the shared common liquid coolant loop 140 via a cooling unit 145, which maintains the temperature of the liquid coolant 141 during operation. The cooling unit 145 may be, for example, a liquid cooler.

[0133] Assuming the traction inverter mentioned above can have a power density of 35 kW / L, its use in factory auxiliary facilities can significantly reduce the footprint of the entire industrial electrolyzer system by 100 or 200.

[0134] To power the unit stack 111 and the entire industrial electrolyzer system 100 or 200, the control system of the traction inverter 110 may need to be adjusted or replaced. Several adjustments or replacements can be made in this regard. For example, the control card on the traction inverter 110 can be replaced with a control card that only allows reverse operation.

[0135] The interface hardware of the traction inverter may also need to be adjusted or replaced so that the traction inverter 110 can power the entire industrial electrolytic cell system 100 or 200. For example, a DC-DC converter may need to be introduced.

[0136] In one example implementation, the pre-charge circuit of the traction inverter can be replaced or adjusted to power the industrial electrolyzer. Since electrical energy is typically introduced from the DC side, the traction inverter can employ capacitors to filter the DC bus voltage and utilize the pre-charge circuit to pre-charge the capacitors. To avoid current spikes caused by large inrush currents, circuits with resistors or active switches can also be used. While necessary for forward operation, these components may be unnecessary when the traction inverter operates only in the reverse direction, as this would require powering the attached industrial electrolyzer. Therefore, such interface hardware can be removed from the traction inverter and replaced by the pre-charge circuit on the AC side of the traction inverter. Preferably, the pre-charge circuit is replaced to charge the load voltage of the industrial electrolyzer to the capacitor voltage in the traction inverter to prevent large inrush currents during startup. Alternatively, when the traction inverter operates in reverse, such interface hardware can be retained and adjusted as a "soft-switching circuit" for the load on the DC side of the traction inverter. An inductor can also be added on the input side to, for example, enable a voltage boost function.

[0137] In some embodiments, both the control system and interface hardware of the traction inverter can be adjusted or replaced to enable the traction inverter to provide power to operate the industrial electrolyzer. Preferably, but not exclusively, the control system of the traction inverter is adjusted or replaced to power the industrial electrolyzer, and the interface hardware of the traction inverter is adjusted or replaced to be able to connect to the electrolyzer; and wherein the pre-charge circuit of the traction inverter is adjusted or replaced to power the industrial electrolyzer.

[0138] On the other hand, traction inverters are provided, in which the control system is replaced with a system capable of detecting the input three-phase voltage waveforms and converting them into controllable DC outputs. This may require additional sensors on the AC side, such as voltage sensors. Sensors may also be needed to facilitate algorithms for determining the phase angle and frequency of the input waveforms. An example of such an algorithm in this regard is a phase-locked loop (FLL).

[0139] With devices such as those described above, the reverse-operated traction inverter 110 can be used to power industrial electrolyzers 100 or 200, thereby increasing the relative overall energy efficiency and reducing the total cost of the entire industrial electrolyzer system 100 or 200.

[0140] Figure 3The above-described method 300 using an embodiment of the invention is schematically depicted. At step 310, individual cells and their electrodes are configured in a cell stack of an industrial electrolyzer to require voltage, current, and power input ranges substantially similar to those of the traction inverter. This may involve configuring: the size of the electrodes in the cell stack to provide a specific range of current; the number of cell electrodes in the cell stack to provide a specific range of voltage; and / or optimizing the cell stack to avoid or minimize the occurrence or impact of “shunt” currents (also known as “bypass” currents) to provide a specific range of power input. At step 320, the control system and / or interface hardware and / or other components of the traction inverter are adjusted or replaced. For example, the control system may be modified to enable constant reverse operation of the traction inverter. In another example, the interface hardware of the traction inverter may be modified. In yet another example, a new control system or interface may be retrofitted; the traction inverter may be connected to the industrial electrolyzer. At step 330, current is transferred from the traction inverter to the industrial electrolyzer.

[0141] Although the invention has been described with reference to specific embodiments, those skilled in the art will understand that the invention can be practiced in many other forms, consistent with the broad principles and spirit of the invention described herein.

[0142] The present invention and the described preferred embodiments specifically include at least one industrially applicable feature.

Claims

1. A system for supplying power to an electrosynthesis unit, the system comprising: Electrosynthesis unit; as well as A traction inverter electrically connected to the electrosynthesis unit, the traction inverter comprising: A control system configured to operate the traction inverter in reverse such that alternating current (AC) input to the traction inverter is converted into direct current (DC) output from the traction inverter, thereby supplying power to the electrosynthesis unit.

2. The system according to claim 1, wherein, The electrosynthesis unit is an industrial electrolytic cell.

3. The system according to claim 1 or 2, wherein, The traction inverter is a vehicle traction inverter.

4. The system according to any one of claims 1 to 3, wherein, The traction inverter includes a liquid cooling system with a coolant.

5. The system according to claim 4, wherein, The liquid cooling system and the coolant are shared by both the traction inverter and the electrosynthesis unit, or the coolant is in fluid communication with both the traction inverter and the electrosynthesis unit.

6. The system according to claim 4 or claim 5, wherein, During operation, the coolant has a maximum coolant temperature of 50 °C or higher.

7. The system according to claim 4 or claim 5, wherein, During operation, the coolant has a maximum coolant temperature of 60 °C or higher.

8. The system according to any one of claims 1 to 7, wherein, During operation, the system has a power density of 5 kW / L or greater.

9. The system according to any one of claims 1 to 7, wherein, During operation, the system has a power density of 18 kW / L or greater.

10. The system according to any one of claims 1 to 9, wherein, During operation, the system has a specific power greater than or equal to 5 kW / kg.

11. The system according to any one of claims 1 to 9, wherein, During operation, the system has a specific power greater than or equal to 18 kW / kg.

12. The system according to any one of claims 1 to 11, wherein, The control system is adjusted from its original configuration to operate the traction inverter in reverse order, thereby supplying power to the electrosynthesis unit.

13. The system according to any one of claims 1 to 11, wherein, The control system was replaced with an alternative control system with a different configuration to operate the traction inverter in reverse to supply power to the electrosynthesis unit.

14. The system according to any one of claims 1 to 13 further includes interface hardware.

15. The system according to claim 14, wherein, The interface hardware is adjusted from its original configuration to enable connection to the electrosynthesizing unit, or the interface hardware is replaced with alternative interface hardware having an alternative configuration to enable connection to the electrosynthesizing unit.

16. The system according to any one of claims 1 to 15, further comprising a pre-charging circuit to provide power to the electrosynthesis unit.

17. The system according to claim 16, wherein, The pre-charge circuit is adjusted from its original configuration to provide power to the electrosynthesis unit, or wherein, The pre-charge circuit is replaced with an alternative pre-charge circuit with an alternative configuration to provide power to the electrosynthesis unit.

18. The system according to claim 14 or claim 16, wherein, The control system of the traction inverter is adjusted or replaced to operate the traction inverter in reverse to supply power to the electrosynthesis unit, and wherein the interface hardware of the traction inverter is adjusted or replaced to be able to connect to the electrosynthesis unit; and wherein the pre-charge circuit of the traction inverter is adjusted or replaced to supply power to the electrosynthesis unit.

19. The system according to any one of claims 1 to 18, wherein, The control system is adjusted to detect whether the alternating current (AC) input to the traction inverter has a three-phase voltage waveform, and if the AC input to the traction inverter has the three-phase voltage waveform, convert the three-phase voltage waveform into direct current (DC) output from the traction inverter.

20. The system according to claim 16 or claim 17, wherein, The pre-charge circuit charges the load voltage of the electrosynthesis unit to the DC bus capacitor voltage in the traction inverter to prevent large inrush currents during system startup.

21. A traction inverter electrically connected to an electrosynthesis unit, the traction inverter comprising: A control system configured to operate the traction inverter in reverse such that alternating current (AC) input to the traction inverter is converted into direct current (DC) output from the traction inverter, thereby supplying power to the electrosynthesis unit.

22. The traction inverter used in the system according to any one of claims 1 to 20.

23. A traction inverter connected to an industrial electrolytic cell, the traction inverter comprising: A control system, wherein the control system is configured to operate in reverse, such that alternating current (AC) is converted into direct current (DC) to supply power to the industrial electrolytic cell. The traction inverter includes a liquid cooling system. Among them, the highest coolant temperature is greater than or equal to 50 ℃. The power density of the traction inverter is greater than or equal to 5 kW / L. The traction inverter has a specific power of 5 kW / kg or greater. The control system of the traction inverter is adjusted or replaced to operate the traction inverter in reverse order, thereby supplying power to the industrial electrolytic cell. The interface hardware of the traction inverter is adjusted or replaced to enable connection to the electrolytic cell, and / or The pre-charging circuit of the traction inverter is adjusted or replaced to supply power to the industrial electrolytic cell.

24. The traction inverter according to claim 23, wherein, The maximum coolant temperature is greater than or equal to 60°C.

25. A traction inverter connected to an industrial electrolytic cell, the traction inverter comprising: A control system, wherein the control system is configured to operate in reverse, such that alternating current (AC) is converted into direct current (DC) to supply power to the industrial electrolytic cell. The traction inverter includes a liquid cooling system. Among them, the highest coolant temperature is greater than or equal to 60 ℃. The power density of the traction inverter is greater than or equal to 18 kW / L. The traction inverter has a specific power of 18 kW / kg or higher. The control system of the traction inverter is adjusted or replaced to operate the traction inverter in reverse order, thereby supplying power to the industrial electrolytic cell. The interface hardware of the traction inverter is adjusted or replaced to enable it to connect to the electrolytic cell; The pre-charging circuit of the traction inverter is adjusted or replaced to supply power to the industrial electrolytic cell. Wherein, the control system is replaced by a control system that detects the input three-phase voltage waveform and converts it into a controllable DC output, and / or The pre-charging circuit is replaced to charge the load voltage of the industrial electrolytic cell to the DC bus capacitor voltage in the traction inverter to prevent large inrush current during startup.

26. A method for supplying power to an electrosynthesis unit, The electrosynthesis unit includes: At least one electrode, which requires a direct current (DC) supply for operation of the electrosynthesis unit; A traction inverter, which is electrically connected to the electrosynthesis unit. The method includes: The traction inverter is operated in reverse such that the alternating current (AC) input to the traction inverter is converted into direct current (DC) output from the traction inverter and supplied to the at least one electrode.

27. The method according to claim 26, wherein, The electrosynthesis unit is an industrial electrolytic cell.

28. The method according to claim 26 or claim 27, wherein, The traction inverter includes a control system, and the control system is configured to operate the traction inverter in reverse.

29. The method according to any one of claims 26 to 28, comprising configuring the electrosynthesis unit and / or the at least one electrode to require a voltage and / or current and / or power input range substantially similar to the voltage and / or current and / or power output range of the traction inverter.

30. The method according to any one of claims 26 to 29, wherein, The traction inverter is a vehicle traction inverter.

31. The method according to any one of claims 26 to 30, further comprising providing a plurality of electrosynthetic units in one or more unit stacks.

32. The method according to claim 29, wherein, Configuring the at least one electrode includes configuring the dimensions of the at least one electrode to provide a selected range of current.

33. The method according to claim 31, wherein, Configuring a single cell in the plurality of electrosynthetic units includes configuring the number of the single cells in the stack of one or more cells to provide a voltage range of selected range.

34. The method according to claim 31, wherein, Configuring a single unit among the plurality of electrosynthetic units includes optimizing the stacking of one or more units to avoid or minimize the occurrence or impact of shunt or bypass currents, thereby providing a selected range of power input.

35. The method according to claim 28, wherein, The control system enables the traction inverter to operate in a constant reverse direction.

36. The method according to claim 28 or claim 35, comprising: The control system detects whether the alternating current (AC) input to the traction inverter has a three-phase voltage waveform, and if the alternating current (AC) input to the traction inverter has the three-phase voltage waveform, the three-phase voltage waveform is converted into direct current (DC) output from the traction inverter.

37. The method according to any one of claims 26 to 36, further comprising a pre-charge circuit, the pre-charge circuit being configured to: The load voltage of the electrosynthetic unit is charged to the DC bus capacitor voltage in the traction inverter to prevent large inrush currents when the electrosynthetic unit starts up.

38. The system, traction inverter, or method according to any one of claims 1 to 37, wherein, The traction inverter has a power output of 50 kW or more.

39. The system, traction inverter, or method according to any one of claims 1 to 38, wherein, The traction inverter is intended or designed to propel non-stationary mobile vehicles.

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