Electrolysis arrangement

Abstract

An electrolysis arrangement (1), comprising a main enclosure (2), wherein the main enclosure (2) comprises a primary level (3) and an least one further level (4, 5), wherein the primary level (3) and the at least one further level (4, 5) are arranged above one another; a plurality of stacks (7) of electrolysis cells configured to obtain an anode product and a cathode product by electrolysis of a medium; one or more anode separators (17) connected to the electrolysis stacks (7) and configured to separate the anode product from the medium, and one or more cathode separators (18) connected to the electrolysis stacks (7) and configured to separate the cathode product from the medium; at least one transformer (9), and a plurality of rectifiers (11); wherein the electrolysis stacks (7) are assigned to groups of electrolysis stacks (7) with each group arranged on a separate level of the main enclosure (2), wherein the rectifiers (11) are assigned to the groups of electrolysis stacks (7) such that each group electrolysis stacks (7) is assigned to one or more rectifiers (11) arranged on the same level as the respective group.

Description

TECHNICAL FIELD

[0001] The invention is directed to an electrolysis arrangement comprising a main enclosure in which electrolysis stacks are arranged.BACKGROUND OF THE INVENTION

[0002] On an industrial scale, electrolysis is usually performed using stacks of electrolysis cells. Each of the electrolysis cells has an anode and a cathode, between which a voltage is applied. Each of the stacks is connected to a transformer, a rectifier and further equipment. Usually, the stacks and the equipment connected thereto are arranged within the same building. Known layouts of electrolysis arrangements require significant space within such a building. This does not only cause significant costs for the building itself. Electrolysis plants typically require significant amounts of space, as conventional electrolysis plants are spread out on the ground. As these plants increase in size, the length of the necessary piping, ductwork, and HVAC systems also grows, which can become quite extensive. The capacity of such plants is often limited by the available area. In densely populated areas, where land is scarce, this poses a significant challenge. As the importance of electrolysis for energy supply continues to grow, finding efficient ways to integrate these systems into limited spaces becomes increasingly critical. This constraint is particularly relevant in urban settings, where expanding infrastructure must be balanced with space availability.

[0003] The object of the invention is to improve the prior art so that an electrolysis arrangement with a more compact layout is obtained.OBJECT OF THE INVENTION

[0004] The object is solved with the electrolysis arrangement according to the independent claim. Advantageous refinements are presented in the dependent claims. The features described in the claims and in the description can be combined with each other in any technologically reasonable manner.

[0005] According to the invention an electrolysis arrangement is presented that comprises a main enclosure, wherein the main enclosure comprises a primary level and an least one further level, wherein the primary level and the at least one further level are arranged above one another; a plurality of stacks of electrolysis cells configured to obtain an anode product and a cathode product by electrolysis of a medium; one or more anode separators connected to the electrolysis stacks and configured to separate the anode product from the medium, and one or more cathode separators connected to the electrolysis stacks and configured to separate the cathode product from the medium; at least one transformer and a plurality of rectifiers; wherein the electrolysis stacks are assigned to groups of electrolysis stacks with each group arranged on a separate level of the main enclosure, wherein the rectifiers are assigned to the groups of electrolysis stacks such that each group is assigned to one or more rectifiers arranged on the same level as the respective group.

[0006] The invention is based on the idea of breaking away from the traditional ground level architecture of electrolysis systems and arranging the electrolysis stacks on different levels in a main enclosure. Due to this stacked arrangement, the spatial footprint of the facility is significantly reduced. Further, stacking the electrolysis stacks on levels above the other and not next to each other shortens the length of the connection lines required, e.g. the conduits to feed the electrolysis products to a common collector or separator and the electrical connection lines.

[0007] The term "electrolysis stack" as used herein refers to a series of connected individual electrolysis cells to increase the production capacity within a single compact unit. This stacking configuration enhances the efficiency and output of the system by allowing multiple cells to operate simultaneously. Preferably, these electrolysis stacks are designed in a modular fashion, allowing multiple electrolysis stacks, preferably the entire group, to be installed and removed as a single unit.

[0008] The electrolysis arrangement can be used for electrolysis of a medium. Preferably, the medium is liquid, in particular water. The medium may contain dissolved salts such as KOH for alkaline electrolysis or electrolysis using anion exchange membrane cells. The electrolysis products are preferably gaseous. In the case of water, hydrogen and oxygen can be obtained as the electrolysis products. The electrolysis arrangement is intended to be used for an industrial scale electrolysis. For example, it is preferred that at least one of the electrolysis products is obtained at a rate of 250 to 1500 Nm 3< per hour per stack. This applies, in particular, to the production of hydrogen in the case of water electrolysis.

[0009] Preferably, the total capacity of the electrolysis arrangement is at least 60 MW. The described electrolysis arrangement is preferably used for industrial scale electrolysis. This is to be understood in contrast to experimental setups on a laboratory scale or electrolysis modules that are marketed as "small-scale power plants". Such "small-scale power plants" are characterized by a lower total capacity and all components of the electrolysis arrangement are installed on a single level within a container-like structure. The industrial scale at which the invention is to be placed can be quantified in terms of the maximum rated DC power consumption of the stacks, here at least 60 MW. The maximum rated DC power consumption is what is commonly used to describe the electrolysis stacks. For example, a "5 MW stack" has a maximum rated DC power consumption of 5 MW.

[0010] The electrolysis arrangement comprises multiple stacks of electrolysis cells arranged in groups, e.g. 2 to 16 stacks per group. Within the stack the electrolysis of the medium can be performed using the electrolysis cells. Thereby, an anode product and a cathode product are obtained. In the case of water as the medium the anode product is oxygen and the cathode product is hydrogen. The anode product and the cathode product can be extracted from the stack.

[0011] Electrolysis stacks within the same group may be driven by a common rectifier or by separate rectifiers arranged on the same level as the respective group, i.e., the electrolysis stacks may each be connected to their own dedicated rectifier. It is also possible to determine sub-groups of one group so that a number of electrolysis cells of a group are fed by one rectifier, while another sub-group of the one group are fed by another rectifier. Electrolysis stacks within one group may be connected to a common transformer or may be connected to their own dedicated transformer. Further, different groups of electrolysis stacks may be connected to a common transformer. It is also possible to determine sub-groups of one group so that a number of electrolysis cells of one group are connected to one transformer, while another sub-group of the one group are connected to another transformer.

[0012] The phrase "assigned to" as used herein may indicate that the power supply for the electrolysis stacks is exclusively provided through the designated rectifier and / or transformer. Thus, the phase "assigned to" may also indicate an electrical connection, e.g., between an electrolysis stack and the designated rectifier.

[0013] The groups of electrolysis stacks on different levels of the main enclosure are spatially separated which emphasizes the modularity of the electrolysis arrangement.

[0014] According to the invention, the main enclosure comprises multiple levels. According to the invention, the electrolysis arrangement comprises at least at least two groups of electrolysis stacks arranged on two different levels of the main enclosure. Preferably, the electrolysis arrangement includes several groups of electrolysis stacks, which are arranged on different levels, e.g., on 2, 3, 4, 5 and even more levels. The main enclosure features a base plate, roof, and walls that define an enclosed space. It includes a primary level, which is preferably the ground floor of the structure, and one or more secondary levels positioned above the primary level. In this context, the term "level" can also be referred to as "story," especially if the enclosure is a building, e.g., a multi-story building. The term "level" should not be interpreted in a strict mathematical sense, but rather as a section of the enclosure with a specific height. Typically, each level has a height ranging from 3 to 8 meters. The term "primary level" is used to distinguish it from the secondary levels located above it.

[0015] The electrolysis arrangement further comprises at least one anode separator and at least one cathode separator. The following description applies to both the anode separator and the cathode separator. The separators are configured for separating the electrolysis products from the medium. If a mixture of the product and the medium is provided to the separator, the mixture is separated within the separator such that only the medium is provided at a separator medium outlet and only the product is provided at a separator product outlet. The medium is preferably liquid, while the products are preferably gaseous. The separators are hence preferably configured as gas / liquid separators. The anode separator and the cathode separator are preferably not connected to each other except for indirect connections via the separator outlets and / or via the separator inlets. The separators may be connected to all electrolysis stacks, i.e., all electrolysis stacks share the same anode separator and the same cathode separator. Alternatively, anode and cathode separators may be connected to one or more of the groups of stacks.

[0016] The electrolysis arrangement further comprises at least one transformer and a plurality of rectifiers for providing electrical energy to the stacks. Each group of electrolysis stacks is electrically connected to one or more rectifiers that are exclusively assigned to that specific group of electrolysis stacks. It is possible to provide more than one group of electrolysis stacks on the same level.

[0017] According to a further embodiment of the invention, the anode and / or the cathode separators are located on the primary level of the main enclosure. It is preferred when two or more groups, e.g. all groups, of electrolysis stacks are assigned a common anode and / or cathode separator. This allows for significant resource and space savings and it reduces the number of necessary connections. Accordingly, in a further embodiment of the invention, the anode and / or cathode separators are each assigned to multiple groups of electrolysis stacks.

[0018] According to a further embodiment of the invention, the anode separator and / or the cathode separator are arranged outside of the main enclosure, preferably in one or more external modules. Preferably, the anode separator and / or the cathode separator extend along a main axis that is oriented perpendicularly to the stacks, i.e., the direction along which the electrolysis cells of a stack are connected. This arrangement is particularly space-efficient.

[0019] According to a further embodiment of the invention, a cooling water supply is provided, in particular a cooling water reservoir, for cooling electrical components of the electrolysis arrangement, such as the rectifier. Usually, cooling water supply requires a significant amount of piping and a considerable amount of energy for pumping the cooling water to the assigned location. It is therefore preferred when the cooling water supply, e.g. cooling water tank, is located on a level above the groups of electrolysis stacks, e.g., on a roof of the main enclosure. This arrangement is not only space-saving but allows the use of gravity to provide to cooling water to designated locations. Additionally, the arrangement of the cooling water above the electrolysis stacks is advantageous in terms of fire safety.

[0020] According to a further embodiment of the invention, the at least one transformer is arranged on the primary level of the main enclosure, wherein the electrolysis arrangement preferably comprises a bus bar connection system extending over multiple floors or levels of the main enclosure to provide electrical energy to the electrolysis stacks. Transformers are very heavy equipment and, as such, are difficult to move and maintain. For this reason, it is suggested to place the one or more transformers on the primary level, e.g., the ground floor. To simplify maintenance and installation of a transformer, a transport system, such as a rail system, can be provided on the primary level. The bus bar connection may connect the one or more transformers with the rectifiers.

[0021] According to a further embodiment of the invention, the electrolysis arrangement comprises a plurality of transformers, wherein each group of electrolysis stacks is assigned to one or more transformers exclusively assigned to the respective group of electrolysis stacks.

[0022] According to a further embodiment of the invention, the at least one transformer is arranged within an external module outside the main enclosure. Each transformer may be housed in its own external module (transformer external module) or multiple transformer may be arranged in a common external module. By placing the transformer outside of the main enclosure, the space within the enclosure can be utilized more efficiently. Additionally, placing the transformer outside of the main enclosure facilitates maintenance and installation. An external module can generally be characterized in that its integration into to the electrolysis arrangement requires only minimal structural modifications of the main enclosure. The main enclosure can be characterized in this context by being prepared for the connection to an external module, for example, that fastening means or electrical connections are prepared for the connection of the module to the main enclosure. External modules, as described herein, can be dimensioned to align with the main enclosure. For example, the width and height of the modules can be coordinated so that the external module matches the height of one level of the main enclosure. The external modules may be standardized units, at least for external modules sharing the same purpose, such as external modules that house the rectifier units. Hence, the external modules may include standardized interfaces or connectors that allow them to easily stack and connect with each other and / or with the main enclosure. This simplifies assembly and integration of the external module's components into the electrolysis arrangement and offers improved flexibility and adaptability, as modules can be customized in various configurations and sizes to fit specific requirements and spatial constraints.

[0023] According to a further embodiment of the invention, the rectifiers are arranged within external modules (rectifier external module) outside the main enclosure. Preferably, the rectifiers are arranged in external modules that are arranged, e.g., stacked, above one another. The external modules may be arranged above the one or more transformers and / or external transformer modules such that the electrical connection length is kept to a minimum. The external modules may be provided with one or more rectifiers on each level on which electrolysis stacks are arranged.

[0024] According to a further embodiment of the invention, the external modules for the rectifiers are adapted for being stacked on top of each other. For this purpose, the external modules may be provided with connection means that allow one module to be placed on top of the other. Prepared connecting means may comprise sections on one module which form receptacles for corresponding sections of another module, the sections corresponding to each other in such a way as to prevent lateral displacement of the modules relative to each other in a horizontal plane.

[0025] According to a further embodiment of the invention, the electrolysis arrangement further comprises a pump unit for driving the medium, wherein the pump unit is arranged outside the main enclosure, preferably within an external module (pump unit external module). Depending on the demands of the electrolysis arrangement, the electrolysis arrangement may comprise one or more pump units. Placing the one or more pump units within an external module facilitates maintenance in that an operator does not have to enter the main enclosure and even an ATEX zone in order to access the pump unit.

[0026] According to a further embodiment of the invention, one or more of the levels of the main enclosure on which electrolysis stacks are placed comprise a lifting system for moving the electrolysis stacks out of or within the main enclosure. Preferably, the lifting system has a lifting capacity that is about 25% to 50% above the load of one or more of the electrolysis stacks or electrolysis stack units. Especially when particularly heavy components, such as transformers, are located on the lowest level of the main enclosure, lifting systems, such as cranes, on the levels where the electrolysis stacks are located can be designed for lighter loads, allowing for easier and more economical maintenance of the electrolysis arrangement.

[0027] According to a further embodiment of the invention, the electrolysis arrangement further comprises a ventilation system for providing a ventilation flow within the main enclosure, wherein for each level containing a group of electrolysis stacks, the ventilation system comprises a first component located outside the main enclosure on the respective level. First components of a ventilation system, in particular a HVAC system may include condensers, which expel heat from the system; air conditioner outdoor units, which contain the compressor and condenser coils or heat pump outdoor units, which function as both condensers and evaporators depending on the mode.BRIEF DESCRIPTION OF THE FIGURE

[0028] In the following, the invention will be described with respect to FIG. 1. The figure shows a preferred embodiment, to which the invention is not limited. The figure and the dimensions shown therein are only schematic. The figure shows a layout of an electrolysis arrangement in accordance with a first embodiment of the invention.

[0029] FIG. 1 shows an embodiment of an electrolysis arrangement 1 comprising a main enclosure 2 in the form of a multi-story construction with four levels. A primary level 3 corresponds to the ground floor of the plane the main enclosure 2 is placed on. The floor of the primary level 3 extends in the direction x and perpendicular to the direction x in the direction y. Direction z indicates the height direction.

[0030] A secondary level 4 is in the height direction z above the primary level 3, and a further secondary level 5, here named third level, is located above the secondary level 4. On top of the third level 5 is the roof level 6 of the main enclosure 2.

[0031] On each of the primary level 3, the secondary level 4 and the third level 5, the electrolysis arrangement 1 comprises a plurality of electrolysis stacks 7. The electrolysis stacks 7 on each of levels 3, 4 and 5 form a separate group of electrolysis stacks.

[0032] Outside of the main enclosure 2 on the ground level 3 is located an extern module 8 housing a plurality of transformers 9. Located on the primary or ground level 3 is further a first external module 10 housing a plurality of first rectifiers 11. Located on the first external module 10 is placed a second external module 12 which is on the same height as the secondary level 4, on the top of which is placed a third external module 13 which is one the same height as the third level 5. The first, second and third external modules 10, 12 and 13 are stacked. The height of said module 10, 12, 13 matches the height of their corresponding level of the main enclosure 2.

[0033] Each of the modules 10, 12 and 13 includes a plurality of rectifiers 11 that are assigned, i.e., electrically connected, to the electrolysis stacks 7 that are provided on the same level of the main enclosure 2 by electrical connections 14. Thus, the first group of electrolysis stacks 7 on the primary level 3 is assigned to the rectifiers 11 in the first external module 10 and is driven by them. The second group of electrolysis stacks 7 on the secondary level 4 is assigned to the rectifiers 11 in the second external module 12 and is driven by them, while the third group of electrolysis stacks 7 on the third level 5 is assigned to the rectifiers 11 in the third external module 13 and is driven by them.

[0034] The external module 8 with the transformers 9 is electrically connected to the first, second and third external modules 10, 12, 13 via bus bar connection 15 to provide electrical power to the rectifiers 11.

[0035] The electrical arrangement further comprises outside the main enclosure 2 an external module 16 with an anode separator 17 and a cathode separator 18. The anode separator 17 and the cathode separator 18 are connected to the electrolysis stacks 5 on each of the levels 3, 4, 5 via piping arrangement 19.

[0036] The electrolysis stacks 7 are configured to obtain by electrolysis of a medium introduced into respective electrolysis stack inlets an anode product provided together with the medium at a respective anode outlet and a cathode product provided together with the medium at a respective cathode outlet. Each of the anode outlets of the electrolysis stacks 7 is connected to a respective anode separator inlet of the anode separator 17 via a distinct line of piping arrangement 19. The anode separator 17 is configured to separate the anode product from the medium introduced into the anode separator inlets such that the anode product is provided at an anode separator product outlet and the medium is provided at an anode separator medium outlet. Each of the cathode outlets of the electrolysis stacks 7 is connected to a respective cathode separator inlet of the cathode separator 18 via a distinct line of piping arrangement 19. The cathode separator 18 is configured to separate the cathode product from the medium introduced into the cathode separator inlets such that the cathode product is provided at a cathode separator product outlet and the medium is provided at a cathode separator medium outlet.

[0037] On each of levels 3, 4 and 5 there is provided a lifting system 20 in the form of a crane. The cranes are arranged underneath the ceiling of the respective level. By means of the lifting system, individual or multiple electrolysis stacks, e.g., electrolysis stack units, can be moved from their respective floor (level) for maintenance operations. Since the heavy components of the system, such as the transformer and the separators, are located on the primary level 3, the loads that the lifting system 20 must handle are relatively low.

[0038] The electrolysis arrangement 2 features a modular design with respect to the components arranged in the main enclosure 2. The primary level 3, the secondary level 4 and the third level 5 of the main enclosure 2 share a common configuration with regard to the arrangement of the electrolysis stacks 7, the rectifiers 11 and the external modules 10, 12, 13. The arrangement can be expanded to additional levels as needed, wherein further external modules for rectifiers can be added to the sides of additional levels of the main enclosure 2. Additional transformers can be accommodated in external module 8. The bus bar connection 15 and the piping arrangement 19 can be extended accordingly.

[0039] On the roof level 6 of the main enclosure 2, a cooling water supply 21 is arranged. Through pipelines (not shown) that connect the cooling water supply 21 with the electrical components of the electrolysis arrangement, the coolant can be delivered to the electrical components by utilizing gravity.

[0040] The electrolysis arrangement further comprises a ventilation, i.e., HVAC system, for providing a ventilation flow within each level 3, 4 and 5 of the main enclosure 2. The HVAC system comprises on each level a first component 22, such as a ventilation duct, located outside the main enclosure 2 on the respective level. The system is also modular with respect to the HVAC system, as each level is equipped with the necessary ventilation components. Each of levels 3, 4, and 5 has its own independent and controlled climate control system.Reference numerals

[0041] 1electrolysis arrangement 2main enclosure 3primary level (ground level) 4secondary level 5third level 6roof level 7electrolysis stack 8external module for transformers 9transformer 10first external module for rectifiers 11rectifiers 12second external module for rectifiers 13third external module for rectifiers 14electrical connection 15bus bar connection 16external module for separators 17anode separator 18cathode separator 19piping arrangement 20lifting system 21cooling water supply 22first component of HVAC system

Claims

1. Electrolysis arrangement (1), comprising: a main enclosure (2), wherein the main enclosure (2) comprises a primary level (3) and an least one further level (4, 5), wherein the primary level (3) and the at least one further level (4, 5) are arranged above one another; a plurality of stacks (7) of electrolysis cells configured to obtain an anode product and a cathode product by electrolysis of a medium; one or more anode separators (17) connected to the electrolysis stacks (7) and configured to separate the anode product from the medium, and one or more cathode separators (18) connected to the electrolysis stacks (7) and configured to separate the cathode product from the medium; at least one transformer (9), and a plurality of rectifiers (11); wherein the electrolysis stacks (7) are assigned to groups of electrolysis stacks (7) with each group arranged on a separate level of the main enclosure (2), wherein the rectifiers (11) are assigned to the groups of electrolysis stacks (7) such that each group of electrolysis stacks (7) is assigned to one or more rectifiers (11) arranged on the same level as the respective group.

2. Electrolysis arrangement (1) according to claim 1, wherein the anode and / or the cathode separators (17, 18) are located on the primary level (3) of the main enclosure (2).

3. Electrolysis arrangement (1) according to any of the preceding claims, wherein the anode and / or the cathode separators (17, 18) are each assigned to multiple groups of electrolysis stacks (7).

4. Electrolysis arrangement (1) according to any of the preceding claims, wherein the anode separator (17) and / or the cathode separator (18) are arranged outside of the main enclosure (2) in one or more external modules (16); preferably, the anode separator (17) and / or the cathode separator (18) are arranged perpendicularly to the electrolysis stacks (7).

5. Electrolysis arrangement (1) according to any of the preceding claims, further comprising a cooling water supply (21), in particular a cooling water reservoir, for cooling electrical components of the electrolysis arrangement (2); wherein the cooling water is supply is arranged on a level (6) of the main enclosure (2) above the groups of electrolysis stacks (7).

6. Electrolysis arrangement (1) according to any of the preceding claims, wherein the at least one transformer (9) is arranged on the primary level (3) of the main enclosure (2); preferably the electrolysis arrangement (2) comprises a bus bar connection system (15) extending over multiple levels (3, 4, 5) of the main enclosure (2) to provide electrical energy to the electrolysis stacks (7).

7. Electrolysis arrangement (1) according to any of the preceding claims, further comprising a plurality of transformers (9), wherein each group of electrolysis stacks (7) is assigned to one or more transformers (9) which are exclusively assigned to the respective group of electrolysis stacks (7).

8. Electrolysis arrangement (1) according to any of claims 6 and 7, wherein the at least one transformer (9) is arranged within an external module (8) outside the main enclosure (2).

9. Electrolysis arrangement (1) according to any of the preceding claims, wherein the rectifiers (11) are arranged within external modules (10, 12, 13) outside the main enclosure (2).

10. Electrolysis arrangement (1) according to claim 9, wherein the external modules (10, 12, 13) for the rectifiers (11) are adapted for being stacked on top of each other.

11. Electrolysis arrangement (1) according to any of the preceding claims, further comprising a pump unit for driving the medium, wherein the pump unit is arranged outside the main enclosure (2), preferably within an external module.

12. Electrolysis arrangement (1) according to any of the preceding claims, wherein one or more of the levels (3, 4, 5) of the main enclosure (2) on which electrolysis stacks (5) are placed comprise a lifting system (20) for moving the electrolysis stacks (7) out of or within the main enclosure (2).

13. Electrolysis arrangement (1) according to any of the preceding claims, further comprising a ventilation system for providing a ventilation flow within the main enclosure (2), wherein for each level (3, 4, 5) containing a group of electrolysis stacks (7) the ventilation system comprises a first component (21) located outside the main enclosure (2) on the respective level (3, 4, 5).

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