High capacity modular electrochemical plant

Abstract

The present disclosure advantageously provides an improved modular electrochemical plant configuration for this large scale power generation. The configurations disclosed herein provide advantages and improvements in the manufacturability and cost of the plant (e.g., through easier and faster onsite assembly), the east of maintenance and access to various components within the plant, a minimized or reduced amount of process piping within the plant, and a minimized or reduced amount of hazardous area within the plant.

Description

HIGH CAPACITY MODULAR ELECTROCHEMICAL PLANT

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 525,861, filed July 10, 2023, which is hereby incorporated by reference in its entirety.FIELD

[0002] The following disclosure relates to an electrochemical plant, and in particular for a high capacity electrochemical plant having a modular configuration.BACKGROUND

[0003] Electrolyzer systems use electrical energy to drive a chemical reaction. For example, water is split to form hydrogen and oxygen. The products may be used as energy sources for later use. In recent years, improvements in operational efficiency have made electrolyzer systems competitive market solutions for energy storage, generation, and / or transport. For example, the cost of generation may be below $10 per kilogram of hydrogen in some cases. Increases in efficiency and / or improvements in operation will continue to drive installation of electrolyzer systems.

[0004] Conventional electrolysis plants are typically configured to operate at power levels in a range of 1-20 megawatts (MW) and tend to be custom designed to fit each customer's use case and site layout. This necessitates unique individual plant layouts and custom equipment packages or, if higher capacity is required (>10 MW), multiple such power plants and integration of smaller-scale modular equipment packages are done on physical site where such plants are constructed.SUMMARY

[0005] In one embodiment, an electrochemical plant is provided, wherein the electrochemical plant includes a power supply section having a plurality of power supply modules positioned in a linear arrangement. The electrochemical plant further includes an electrochemical stack section having a plurality of electrolysis modules positioned in a linear arrangement adjacent to and connected with the plurality of power supply modules. The electrochemical plant further includes a process equipment section including a plurality of processing modules positioned in a linear arrangement adjacent to and connected with the plurality of electrolysis modules and / or the plurality of power supply modules. Theelectrochemical plant further includes a cooling section including a plurality of cooling modules positioned in a linear arrangement adjacent to and connected with one or more of the plurality of power supply modules, the plurality of electrolysis modules, or the plurality of processing modules. Each module of the plurality of power supply modules, the plurality of electrolysis modules, the plurality of processing modules, and the plurality of cooling modules is configured to be manufactured off-site (e.g., at an offsite fabrication / manufacturing facility) and transported to a location of the electrochemical plant for installation and connection with one or more additional modules of the plurality of power supply modules, the plurality of electrolysis modules, the plurality of processing modules, and the plurality of cooling modules. In certain examples, each module may be configured to be manufactured at or procured from an offsite fabrication / manufacturing facility as a standardized "off-the-shelf" module that may be shipped to any modular electrochemical plant location for installation at that particular location (i.e., the modules do not necessarily need to be fabricated for a specific plant).

[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Exemplary embodiments are described herein with reference to the following drawings.

[0008] Figure 1A depicts an example of an electrochemical or electrolytic cell.

[0009] Figure IB depicts an example of a system including an electrochemical stack having a plurality of electrochemical cells of Figure 1A.

[0010] Figure 2 depicts an example of a modular configuration of an electrochemical plant.

[0011] Figure 3 depicts an additional example of a modular configuration of an electrochemical plant.

[0012] Figures 4A and 4B depict examples of an electrolysis module having four electrochemical stacks.

[0013] Figures 5A and 5B depict examples of process equipment modules related to feed water treatment.

[0014] Figures 6A and 6B depict examples of additional modules within the process equipment section of the plant configured to provide anode water and cooling water to the electrochemical stacks and receive anode product (e.g., water and oxygen gas) from the stacks.

[0015] Figures 7A and 7B depict examples of additional modules within the process equipment section of the plant configured to provide cathode water and cooling water to the electrochemical stacks and receive cathode product (e.g., water and hydrogen gas) from the stacks.

[0016] Figures 8A and 8B depict examples of an additional module within the process equipment section of the plant configured to process the hydrogen gas from the cathode outlet / cathode separator within Figures 7A and 7B and provide the desirable hydrogen gas product.

[0017] Figures 9A-9C depict examples of modules including a cathode heat exchanger and an anode heat exchanger configured to interact with the cooling modules and power electronic modules via power supply cooling lines.

[0018] Figure 10 depicts an additional example of a modular configuration of an electrochemical plant.

[0019] Figure 11 depicts an additional example of a modular configuration of an electrochemical plant.

[0020] Figure 12 depicts an example communication system between an electrochemical plant or component thereof and a computing device having a controller over a connected network.

[0021] Figure 13 depicts an example of a computing device having a controller.DETAILED DESCRIPTION

[0022] The present disclosure advantageously provides an improved modular electrochemical plant configuration for this large scale power generation. The configurations disclosed herein provide advantages and improvements in the manufacturability and cost of the plant (e.g., through easier and faster onsite assembly), theeast of maintenance and access to various components within the plant, a minimized or reduced amount of process piping within the plant, and a minimized or reduced amount of hazardous area within the plant.Electrochemical Cells / Stacks

[0023] Figure 1A depicts an example of an electrochemical cell for the production of hydrogen gas and oxygen gas through the splitting of water. The electrochemical cell includes a cathode, an anode, and a membrane positioned between the cathode and anode. Within the water-splitting electrolysis reaction, one interface runs an oxygen evolution reaction (OER) while the other interface runs a hydrogen evolution reaction (HER). For example, the anode reaction is H2O^2H++1 / 2O2+2e and the cathode reaction is 2H++2e->H2. The water electrolysis reaction has recently assumed great importance and renewed attention as a potential foundation for a decarbonized "hydrogen economy."

[0024] Figure IB depicts an example of a system including an electrochemical stack having a plurality of electrochemical cells of Figure 1A. In certain examples, the electrochemical stacks may contain 50-1000 cells, 50-100 cells, 500-700 cells, or more than 1000 cells. Any number of cells may make up a stack. The electrochemical cells within the electrochemical stack may be configured to operate with 200 mV or less of pure resistive loss when operating at a high current density (e.g., at least 3 Amps / cm2, at least 4 Amps / cm2, at least 5 Amps / cm2, at least 6 Amps / cm2, at least 7 Amps / cm2, at least 8 Amps / cm2, at least 9 Amps / cm2, at least 10 Amps / cm2, at least 11 Amps / cm2, at least 12 Amps / cm2, at least 13 Amps / cm2, at least 14 Amps / cm2, at least 15 Amps / cm2, at least 16 Amps / cm2, at least 17 Amps / cm2, at least 18 Amps / cm2, at least 19 Amps / cm2, at least 20 Amps / cm2, at least 25 Amps / cm2, at least 30 Amps / cm2, in a range of 1-30 Amps / cm2, in a range of 3-20 Amps / cm2, in a range of 3-15 Amps / cm2, in a range of 3-10 Amps / cm2, or in a range of 10-20 Amps / cm2).

[0025] As illustrated in the system of Figure IB, water (H2O) may be supplied to the anodic inlet of an electrolytic cell stack 12. In some embodiments, only the anodic inlet of the cell stack 12 may receive water. In these embodiments, the cathode side of the cell stack 12 may not receive water (e.g., a dry cathode side may be used). In anotherembodiment, a cathode inlet may also receive water, wherein the water may be supplied to the cathode inlet to cool the cell stack 12 during electrolysis.

[0026] The water supplied to the anodic inlet flows to an anodic inlet manifold that distributes the water to the anode side of the plurality of cells contained with the cell stack 12. In embodiments where water is supplied to the cathode inlet, water supplied to the cathode inlet flows to a cathodic inlet manifold that distributes the water to the cathode side of the plurality of cells in the cell stack 12. In certain examples, the amount of water (e.g., deionized (DI) water) transferred to or circulated through each cell of the electrochemical stack 12 may be in a range of 0.25-1 mL / Amp / cell / min, in a range of 0.25-5 mL / Amp / cell / min, or in a range of 0.5-1 mL / Amp / cell / min.

[0027] During electrolysis, oxygen (O2) is produced at the anode side of the electrolytic cells and hydrogen (H2) is produced at the cathode side of the electrolytic cells. Specifically, a water splitting electrolysis reaction is configured to take place within each individual cell in the cell stack 12. Each cell includes one interface (the anode side of the cell) configured to run an oxygen evolution reaction (OER) and another interface (the cathode side of the cell) configured to run a hydrogen evolution reaction (HER), such as depicted in Figure 1A.

[0028] During electrolysis, some of the water supplied to the anode side of an electrolytic cell may not be converted into oxygen. Accordingly, a two-phase flow of oxygen and unreacted water is outlet from each of the anode sides of the cells into an anodic outlet manifold 13. The two-phase flow of oxygen and unreacted water flows from out of the cell stack 12 through the anodic outlet manifold 13.

[0029] Additionally, as noted above, in some embodiments, water may be supplied to the cathode side of the cell stack as a coolant. Accordingly, a two-phase flow of hydrogen and water is outlet from each of the cathode sides of the cells to a cathodic outlet manifold 14. The two-phase flow of hydrogen and water flows out of the cell stack 12 through the cathodic outlet manifold 14.Electrochemical Plant

[0030] The electrochemical cells and stacks discussed within Figures 1A and IB may be incorporated into an electrochemical plant having a plurality of electrochemical stacks (i.e., at least two stacks).

[0031] The plurality of electrochemical stacks may be used in the formation of a large- scale electrochemical plant that may be configured to generate at least 1,000 kg / day, at least 5,000 kg / day, or at least 10,000 kg / day of hydrogen gas using continuous operation. In certain examples, the hydrogen gas generated in the plurality of electrochemical stacks may be aggregated and supplied to an end user / customer with a purity of at least 98% at a pressure of at least 20 atm.

[0032] In other embodiments, the plurality of electrochemical stacks may be used in the formation of a large-scale electrochemical plant that may be configured to generate at least 10 megawatts (MW) of power, at least 25 MW, at least 50 MW, at least 75 MW, at least 100 MW, in a range of 10-100 MW, in a range of 25-100 MW, or in a range of 50-100 MW.

[0033] The electrochemical stacks may be incorporated within an improved modular electrochemical plant configuration for this large scale power generation. These modular configurations provide advantages and improvements in the manufacturability and cost of the plant (e.g., through easier and faster onsite assembly), the east of maintenance and access to various components within the plant, a minimized or reduced amount of process piping within the plant, and a minimized or reduced amount of hazardous area within the plant.

[0034] Through a modular configuration, the electrochemical plant advantageously allows for cost reductions and optimizations in manufacturing and installation, as well as improvements in scalability or additions to existing modular plant installations. This may allow for repeated or mass deployments of various electrochemical plants or sub- units / components to a broad range of potential locations. Further, partially as a result of the improved modular configuration, the cost per unit of installed capacity is advantageously significantly reduced in comparison to a conventional electrochemical plant of similar capacity.

[0035] Figure 2 depicts one example of an advantageous modular configuration of an electrochemical plant. In this particular example, the electrochemical plant is arranged or positioned in four distinct sections or segments. Specifically, the figure identifies a power supply section, an electrochemical stack section, a process equipment section, and a cooling section. Each section may advantageously include one or more modules configured to be manufactured off-site, delivered to the site, and installed / connected to the surrounding equipment with minimal or reduced on-site labor. Centralized piping and electrical cables may be provided within this modular configuration to connect various modules to each other.

[0036] The size of the modules may be designed to be positioned on a skid and transported from the manufacturing site to the plant site via truck. In such instances, the maximum size of an individual module may be 3.65 meters wide by 3.65 meters tall by 14.63 meters long (12 feet wide by 12 feet tall by 48 feet long). In other examples, the maximum size of an individual module may be 4.27 meters wide by 4.27 meters tall by 18.29 meters long (14 feet wide by 14 feet tall by 60 feet long).

[0037] Additionally, the overall weight of the module and truck / trailer may be limited to 36,287 kg (80,000 pounds) or 54,431 kg (120,000 pounds).

[0038] The modules may be manufactured off-site or procured from an offsite manufacturing facility as a standardized off-the-shelf module. The modules may include components that are attached to or welded to structural elements (e.g., I-beams), which may be powder coated to provide corrosion resistance. Additionally, mesh grates may be positioned over the structure to allow an operator to stand and work on the module.

[0039] Through this arrangement or configuration, additional modules may be added to the plant layout to increase the plant capacity more readily or easily as needed. For example, additional power supply modules may be added to correspond with additional stack modules. Further, additional cooling modules may be added to correspond with the additional power supply and stack modules. In some examples, the process equipment may be sized configured to accommodate or process a certain amount of added volume created by the added stack modules. Following a known expansion or addition in stack modules orvolume, an additional set of process equipment may be added to accommodate the added volume.

[0040] The additional modules may be positioned in line with those modules already in place; the same applies for the array of coolers, which may be connected in parallel to a singular manifold. Should maintenance need to be done, or should a full skid need to be removed and replaced, the layout described allows ample access area for maintenance personnel, equipment, and vehicles.

[0041] In other words, because the modules within a specific section of the plant are arranged in a linear fashion, additional modules may be added to the plant at one or both ends of the linear arrangement of the section with no rearrangement of the plant design at all. For example, an additional power supply module may be added at the top of the linear arrangement depicted in Figure 2, along with an additional electrochemical stack module, and an additional cooling module at the top of the respective linear arrangement.

[0042] Figure 3 depicts an additional example of a modular configuration of an electrochemical plant. Similar to the example in Figure 2, this electrochemical plant includes four distinct sections or segments: a power supply section, an electrochemical stack section, a process equipment section, and a cooling section. Each section may advantageously include one or more modules configured to be manufactured off-site, delivered to the site, and installed / connected to the surrounding equipment with minimal or reduced on-site labor. In certain examples, each module may be configured to be manufactured at or procured from an offsite fabrication / manufacturing facility as a standardized "off-the-shelf" module that may be shipped to any modular electrochemical plant location for installation at that particular location (i.e., the modules do not necessarily need to be fabricated for a specific plant).

[0043] In this particular example, the electrochemical plant includes a power supply section having four power supply modules 22 positioned in a linear arrangement and a power distribution center 24. In this particular example, each power supply module 22 includes two power supply units with centralized connections between the two units configured to supply power to a load (e.g., an electrochemical stack, a processing unit, or acooling unit within the plant). Additional or fewer power supply units may be developed / built with each power supply module.

[0044] Each power supply module 22 may be spaced apart from each adjacent component or module of the power supply section to provide adequate access space to the power supply module. For instance, a lane having a width of at least 3 meters, at least 4 meters, or at least 5 meters may be provided between adjacent modules to allow for a forklift, a boom truck or crane, or an operator to access the area to provide maintenance to the specific module.

[0045] The power supply units within the power supply modules 22 may be connected to and receive energy from the power grid or a renewable energy power source (e.g., a solar plant, windfarm, fuel cell array). In certain examples, each power supply module and the plurality of power supply units within the power supply modules may be connected to a single input source of power. Each power supply module may be developed / manufactured off-site and transported to the plant site on a skid for quicker installation with the surrounding plant sections. In certain examples, each skid may be transported and installed onsite using pylons, concrete slabs, or screws / helical piles, which advantageously eliminate a need for large volumes of poured concrete at the plant site.

[0046] The power supply modules may further include one or more medium voltage transformers and one or more AC-to-DC power converters. For example, the transformers may be configured to convert 6.25 MW of 34.5 kV AC to 820 V AC to feed the AC-to-DC power converters. The power converters may then transfer DC power through busbars to the electrochemical stack section.

[0047] In various implementations, the power supply modules may further include a rectifier and / or inductor to support adaptation of power from the power grid and provide power to a plurality of electrochemical stacks connected in series.

[0048] In certain examples, the power supply section of the electrochemical plant may include a power distribution center or building 24. The power distribution center 24 may be positioned in a central location between two power supply modules in the linear arrangement of the power supply section of the plant. The power distribution center 24 may include a motor control center, a process logic controller, and an operator station,wherein the power distribution center is configured to control the power distribution to the electrochemical stacks and the operation of the electrochemical stack section, process equipment section, and cooling section.

[0049] As depicted in Figure 3, the electrochemical plant may include a plurality of electrolysis modules 26 positioned in a linear arrangement in the center of the plant for ease of deployment or for capacity additions. Fewer or more modules may be present within the plant. Further, as shown in Figure 3, the electrolysis modules 26 may be positioned adjacent to the power supply modules 22. In this particular example, one electrolysis module is configured to be connected to and receive power from a single power supply module. Alternative arrangements are also possible wherein two power supply modules provide power to a single electrolysis module, or a single power supply module provides power to two electrolysis modules.

[0050] In this particular example, each electrolysis module 26 includes four separate electrochemical stacks. Fewer or more stacks may be present for a particular module. Advantageously, each module 26 is configured to be manufactured off-site and transported to the plant site on a skid for quicker installation with the surrounding plant sections. Each skid containing each module within the electrochemical stack section may be transported and installed onsite using pylons, concrete slabs, or screws / helical piles, which advantageously eliminate a need for large volumes of poured concrete at the plant site.

[0051] In this particular example, centralized piping and electrical cables may be present within each module and between the various electrolysis modules. For example, a first electrolysis module 26 may have shared piping distributing the inlet water to the various stacks as well as shared piping for collecting / transferring the produced hydrogen and shared piping for collecting / transferring the produced oxygen from the stacks. In one example, four stacks within a single electrolysis module 26 may be connected and fed with single continuous manifold and are capable of generating at least 1,000 kg / day, at least 5,000 kg / day, or at least 10,000 kg / day of hydrogen gas using continuous operation.

[0052] Further, shared and centrally located electrical cables may be provided from a power supply module 22 adjacent to the respective stack module.

[0053] In certain examples, a minimized amount of piping may be configured to attach one electrolysis module with an additional, adjacent electrolysis module. The modular arrangement allows for each module to be built such that an additional stack may readily be added to the plant through the quick attachment of the inlet and outlet piping lines between adjacent modules. For example, a second electrolysis module 26 may be manufactured off-site (similarly to the first electrolysis module), transported to the plant site, and positioned adjacent to first electrolysis module such that the pre-configured piping of the first and second electrolysis modules 26 may be aligned with each other and attached to each other, therein providing a quick expansion of the size of the electrochemical plant with minimized on-site manufacturing / installation time and cost.

[0054] In certain examples, each electrolysis module may be manufactured off-site such that each electrolyzer stack within the respective module is positioned at least 0.5 meters, at least 1 meter, at least 2 meters, at least 3 meters, or at least 5 meters off of the ground. This advantageously allows for piping (e.g., stack inlet water supply piping, water return piping, coolant supply / return piping) to pass underneath the various stacks in the installed location onsite.

[0055] Figures 4A and 4B depict examples of an electrolysis module having four electrochemical stacks. In these figures, piping (e.g., anode inlet, cathode inlet, anode outlet, cathode outlet, and cooling lines) may be positioned to run underneath the electrolysis module positioned off of the ground. In the limited amount of space around the electrolyzer stack, access for electrical connections, fluid connections, and operations and maintenance are desirable. To maximize the amount of space available, the primary fluid system headers may be run under the electrolysis stacks, as shown within the figures, resulting in one additional side, or the top of the stack, being 'open' for other uses.

[0056] Each electrolysis module may be manufactured off-site to varying degrees of weatherization based on the final i nsta I lation / pla nt location, wherein various components within the module may be enclosed, insulated, or heated (e.g., heat traced).

[0057] Additionally, each electrolysis module may be positioned on-site such that the modules have a specific amount of clearance in front of them (e.g., between the electrolysis modules and the power supply and / or between the electrolysis modules and the processequipment) to provide adequate access space to maintain the modules. For instance, a lane having a width of at least 2 meters, at least 3 meters, at least 4 meters, or at least 5 meters may be provided between the electrolysis modules and the process equipment and / or the power supply to access the area to provide maintenance to each electrolysis module.

[0058] In certain examples, while not depicted in Figures 4A and 4B, the electrolysis modules may include a barrier or (e.g., metal) sheet positioned below the piping and above the ground, therein providing a protective divider between the hydrogen gas within certain outlet piping lines coming from the electrochemical stacks and a plant operator. As noted here, areas containing hydrogen gas may be considered a hazardous area (identified as Class 1, Division 2) within the plant, requiring additional safety equipment / monitoring. Through the addition of a barrier / divider, the electrolysis modules, or certain areas of the electrolysis modules near the ground may no longer be labeled as a hazardous area. Through this arrangement, the overall hazardous area and / or overall footprint of the plant may be reduced.

[0059] Returning to Figure 3, the electrochemical plant further includes a process equipment section or segment of the plant that may be positioned in a linear arrangement between the electrochemical stack section and the cooling section. The process equipment section, like the other sections of the plant, may include one or more processing modules developed / manufactured off-site and transported to the plant site on skids for quicker installation with the surrounding plant sections (e.g., via piping and / or electrical cables). Each skid containing each module within the process equipment section may be transported and installed onsite using pylons, concrete slabs, or screws / helical piles, which advantageously eliminate a need for large volumes of poured concrete at the plant site.

[0060] For example, the process equipment section may include various modules or skids such as an anode / cathode gas separation module, a hydrogen product processing module, a feed water treatment module, and / or a process water heat exchange and pumping module. Fewer or additional modules may also be included, depending on the overall size of the plant, and the amount of process equipment that can be developed or manufactured off-site on an individual skid. In certain examples, the hydrogen product processing module may be developed or manufactured off-sit to include a condenser, awater knockout drum and coalescing filter, allowing for a high hydrogen purity product 60 to be achieved without a need for a dedicated dryer module.

[0061] As depicted in Figure 3, the process equipment section of the electrochemical plant may include a RO / DI unit 28 configured to receive utility water 54 and send off waste water 56, an oxygen separator 30, a makeup water module 32, a makeup water tank 34, a hydrogen separator 36, a hydrogen cooler module 38, an anode water pump module 40, a cooling water pump module 42, a cathode water pump module 44, cathode pumps 46, an air compressor 48, a chiller 50, one or more vent stacks 58, and a nitrogen rank 62, for example.

[0062] Conventionally, larger scale electrolyzer plants custom design and install the process equipment onsite. By integrating the process equipment onto skids / modules offsite and shipping the preconfigured modules to the plant site, field installation efforts may be minimized in favor of factory integration. This lowers the costs and allows for mass production of the process skids. In other words, modules manufactured and preconfigured off-site may include pumps, heat exchangers, separators, polishing beds, and / or other equipment pre-installed, such that such equipment does not need to be installed on-site where hydrogen is produced.

[0063] Figures 5A and 5B depict examples of process equipment modules related to feed water treatment, water circulation, and anode / cathode water level balancing. For example, a module may be associated with a RO / DI (reverse osmosis / deionization) water treatment module configured to receive utility water and treat the utility water for use within the electrochemical stacks. An additional module may be associated with the makeup water tank configured to receive the treated water from the RO / DI module and provide water to the anode and cathode gas separators for distribution to the electrochemical stacks. In some examples, the anode gas separator has a volume or capacity of at least 12,000 liters, and the cathode gas separator has a volume or capacity of at least 3,500 liters. With such capacities, the anode and cathode separators may be configured to process or accommodate an electrochemical plant configured to generate or produce at least 10,000 kg / day of hydrogen gas. In certain examples, the hydrogen gas generated in theelectrochemical plant may be aggregated and supplied to an end user / customer with a purity of at least 98% at a pressure of at least 20 atm.

[0064] Figures 6A and 6B depict examples of additional modules within the process equipment section of the plant configured to provide anode water and cooling water to the electrochemical stacks and receive anode product (e.g., water and oxygen gas) from the stacks.

[0065] Figures 7A and 7B depict examples of additional modules within the process equipment section of the plant configured to provide cathode water and cooling water to the electrochemical stacks and receive cathode product (e.g., water and hydrogen gas) from the stacks.

[0066] Figures 8A and 8B depict examples of an additional module within the process equipment section of the plant configured to process the hydrogen gas from the cathode outlet / cathode separator within Figures 7A and 7B and provide the desirable hydrogen gas product.

[0067] Returning to Figure 3, a particular arrangement or configuration of the modules within the electrochemical stack section and specific modules or skids within the process equipment section may advantageously minimize the hazardous section or area of the overall electrochemical plant. Specifically, the areas containing hydrogen gas (identified as Class 1, Division 2) within the plant may be minimized through the positioning of specific modules within the process equipment section adjacent to each other and adjacent to the modules within the electrochemical stack section. This may include all of the electrolysis modules that produce hydrogen through the water splitting reaction, as well as the hydrogen product processing and makeup water modules in the process equipment section. The circled area / enclosure 64 within Figure 3 identifies the hazardous area or section of the plant that includes these specific modules. Through this arrangement, the overall hazardous area of the plant may be minimized. For example, less than one third (33%) of the total plant area may be designated as a hazardous area, therein reducing or minimizing the cost / amount of safety equipment required for the plant.

[0068] As depicted in Figure 3, the electrochemical plant further includes a cooling section or segment of the plant that may be positioned in a linear arrangement adjacent tothe process equipment section. Again, like the other sections of the plant, the cooling section of the plant may include one or more cooling modules 52 developed / manufactured off-site and transported to the plant site on skids for quicker installation with the surrounding plant sections (e.g., via piping and / or electrical cables). The linear arrangement of cooling modules may be advantageous as well in simplifying and expediting the addition or removal of cooling modules as cooling requirements for the plant change over time. Each skid containing each cooling module within the cooling section may be transported and installed onsite using pylons, concrete slabs, or screws / helical piles, which advantageously eliminate a need for large volumes of poured concrete at the plant site.

[0069] Piping and electrical cables to the cooling modules may also be configurable for ease of attachment or disconnection, allowing each cooling module to be isolated or taken off-line for maintenance, when necessary.

[0070] The cooling section may include a plurality of dry or wet coolers configured to transfer and reject the waste heat (i.e., into the surrounding plant environment) that has been generated in the electrochemical stacks through the water splitting reactions. Additionally, as a result of the single, linear arrangement, other methods for cooling may readily take the place of the dry coolers without affecting any equipment positioning on other process system skids.

[0071] The cooling section may be in fluid communication with additional process equipment modules for cooling various components within the plant. For example, Figures 9A-9C depict examples of modules including a cathode heat exchanger and an anode heat exchanger configured to interact with the cooling modules and power electronic modules via power supply cooling lines. The plurality of dry or wet coolers within the cooling modules may be connected (e.g., in parallel) to a same / singular manifold.

[0072] Returning to the overall electrochemical plant, Figure 10 depicts an additional example of a modular configuration of an electrochemical plant. In this figure, dashed lines with arrows are identified around various modules of the power supply section, electrochemical stack section, process equipment section, and cooling section. These dashed lines identify access areas between modules that are wide enough to allow for a forklift, a boom truck or crane, or an operator to access the area to provide maintenance tothe specific module. As noted above, these access lanes may be at least 2 meters, at least 3 meters, at least 4 meters, or at least 5 meters wide, for example, to provide adequate access for maintenance. As identified within the figure, these access lanes are present between modules in the power supply section, between the electrochemical stack section and the process equipment section, and between the process equipment section and the cooling section. Further, access lanes may also be provided around the exterior of the plant (e.g., to access the cooling modules and / or power supply modules).

[0073] Figure 11 depicts an additional example of a modular configuration of an electrochemical plant. In this figure, two sets of isolation valves are present in the piping lines between electrolysis module B and electrolysis module C. Such isolation valves may be advantageous is closing off the water inlet lines and production outlet lines from a particular module or group of modules to allow the electrochemical plant to run at a reduced capacity. For example, in Figure 10, a first set of isolation valves adjacent to electrolysis module B may be closed off, therein shutting down flow to and from electrolysis module B and connected module A, therein only operating electrolysis modules C and D (i.e., operating the plant at 50% capacity). Alternatively, the second set of isolation valves adjacent to electrolysis module C may be closed off, therein shutting down flow to and from electrolysis module C and connected module D, therein only operating electrolysis modules A and B (i.e., operating the plant at 50% capacity).

[0074] While not depicted in Figure 10, additional isolation valves may be present between electrolysis modules A and B and / or between electrolysis modules C and D. This may advantageously allow for even greater variability in the plant operation. That is, the plant could operate at 25%, 50%, 75%, or 100% capacity based on whether or not certain isolation valves are closed or open. For example, isolation valves between electrolysis modules A and B may be closed, while the remaining valves are open, therein operating modules B, C, and D (i.e., at 75% capacity). Alternatively, isolation valves between electrolysis modules A and B may be closed, and the isolation valves adjacent to electrolysis module C may also be closed, therein only operating module B (i.e., at 25% capacity).Attaching Modular Units Together

[0075] As noted above, the manufacture of a multiple modular units off-site requires some assembly and connection with other modular units after shipment to the plant site. There are challenges in such connection of piping and electrical cables between such large modules after delivery to the plant site. For example, there may be errors in the exact placement of a fluid port or a mechanical system relative to a module's datum. This may cause challenges or misalignments between modules during onsite assembly.

[0076] Misalignments may be corrected or minimized through one or more of the following solutions.

[0077] For one, flexible couplings may be provided between rigid ports between modules. For example, an inlet water line may extend between two adjacent electrochemical modules. The rigid piping present in the first module and the second module may be connected to each other using a flexible coupling that allows for a minor adjustment or correction in the flow path between the two rigid pipes without requiring a large scale reconfiguration of the piping arrangement (therein reducing costs and time for installation).

[0078] Additionally, or alternatively, shims may be installed within or beneath a module to adjust the arrangement of certain piping of the module relative to an adjacent module. Again, this may provide a less costly fix to a misalignment between two modules without requiring a large scale reconfiguration of a piping arrangement.

[0079] Additionally, or alternatively, misalignments between modules may be alleviated through the use of long length piping segments with bends between modules. The use of longer length piping may allow for a certain degree of flex within the pipe to accommodate a minor misalignment.

[0080] Additionally, or alternatively, the foundation of the plant site may be examined (e.g., laser scanned) to provide information or validation regarding the modular manufacturing offsite (i.e., that the modules will assemble as expected, or that adjustments in the piping arrangement may be needed prior to deployment to the plant site).Controlling Operation of the Electrochemical Plant or a Component Thereof

[0081] Figure 12 illustrates an exemplary system 120 for controlling operation of an electrochemical plant or a component / module thereof (e.g., one or more electrochemical stacks). The system 120 includes the electrochemical plant / stack 10 (such as depicted in Figure 3), a monitoring system 121, a workstation 128, and a network 127. Additional, different, or fewer components may be provided.

[0082] The monitoring system 121 includes a server 125 and a database 123. The monitoring system 121 may include computer systems and networks of a system operator (e.g., the operator of the electrochemical cell / stack 10). The server database 123 may be configured to store information regarding the operating conditions or setpoints for optimizing the performance of the electrochemical plant / stack 10.

[0083] The monitoring system 121, the workstation 128, and the electrochemical cell / stack 10 are coupled with the network 127. The phrase "coupled with" is defined to mean directly connected to or indirectly connected through one or more intermediate components. Such intermediate components may include hardware and / or software-based components.

[0084] The optional workstation 128 may be a general-purpose computer including programming specialized for providing input to the server 125. For example, the workstation 128 may provide settings for the server 125. The workstation 128 may include at least a memory, a processor, and a communication interface.

[0085] Figure 13 illustrates an exemplary server 125 of the system of Figure 12. The server 125 includes a memory 301, a controller or processor 302, and a communication interface 305. The server 125 may be coupled to a database 123 and a workstation 128. The workstation 128 may be used as an input device for the server 125. The communication interface 305 receives data indicative of use inputs made via the workstation 128 or a separate electronic device.

[0086] The controller or processor 302 may include a general processor, digital signal processor, an application specific integrated circuit (ASIC), field programmable gate array (FPGA), analog circuit, digital circuit, combinations thereof, or other now known or later developed processor. The controller or processor 302 may be a single device or combinationof devices, such as associated with a network, distributed processing, or cloud computing that is configured to control operation of one or more components of the electrochemical plant or stack.

[0087] The memory 301 may be a volatile memory or a non-volatile memory. The memory 301 may include one or more of a read only memory (ROM), random access memory (RAM), a flash memory, an electronic erasable program read only memory (EEPROM), or other type of memory. The memory 301 may be removable from the device 122, such as a secure digital (SD) memory card.

[0088] The communication interface 305 may include any operable connection. An operable connection may be one in which signals, physical communications, and / or logical communications may be sent and / or received. An operable connection may include a physical interface, an electrical interface, and / or a data interface. The communication interface 305 provides for wireless and / or wired communications in any now known or later developed format.

[0089] In the above-described examples, the network 127 may include wired networks, wireless networks, or combinations thereof. The wireless network may be a cellular telephone network, an 802.11, 802.16, 802.20, or WiMax network. Further, the network 127 may be a public network, such as the Internet, a private network, such as an intranet, or combinations thereof, and may utilize a variety of networking protocols now available or later developed including, but not limited to TCP / IP based networking protocols.

[0090] While the non-transitory computer-readable medium is described to be a single medium, the term "computer-readable medium" includes a single medium or multiple media, such as a centralized or distributed database, and / or associated caches and servers that store one or more sets of instructions. The term "computer-readable medium" shall also include any medium that is capable of storing, encoding, or carrying a set of instructions for execution by a processor or that cause a computer system to perform any one or more of the methods or operations disclosed herein.

[0091] In a particular non-limiting example, the computer-readable medium can include a solid-state memory such as a memory card or other package that houses one or more non-volatile read-only memories. Further, the computer-readable medium can be arandom-access memory or other volatile re-writable memory. Additionally, the computer- readable medium can include a magneto-optical or optical medium, such as a disk or tapes or other storage device to capture carrier wave signals such as a signal communicated over a transmission medium. A digital file attachment to an e-mail or other self-contained information archive or set of archives may be considered a distribution medium that is a tangible storage medium. Accordingly, the disclosure is considered to include any one or more of a computer-readable medium or a distribution medium and other equivalents and successor media, in which data or instructions may be stored.

[0092] In an alternative example, dedicated hardware implementations, such as application specific integrated circuits, programmable logic arrays and other hardware devices, can be constructed to implement one or more of the methods described herein. Applications that may include the apparatus and systems of various examples can broadly include a variety of electronic and computer systems. One or more examples described herein may implement functions using two or more specific interconnected hardware modules or devices with related control and data signals that can be communicated between and through the modules, or as portions of an application-specific integrated circuit. Accordingly, the present system encompasses software, firmware, and hardware implementations.

[0093] In accordance with various embodiments of the present disclosure, the methods described herein may be implemented by software programs executable by a computer system. Further, in an exemplary, non-limited embodiment, implementations can include distributed processing, component / object distributed processing, and parallel processing. Alternatively, virtual computer system processing can be constructed to implement one or more of the methods or functionalities as described herein.

[0094] Although the present specification describes components and functions that may be implemented in particular embodiments with reference to particular standards and protocols, the claim scope is not limited to such standards and protocols. For example, standards for Internet and other packet switched network transmission (e.g., TCP / IP, UDP / IP, HTML, HTTP, HTTPS) represent examples of the state of the art. Such standards are periodically superseded by faster or more efficient equivalents having similar functions.Accordingly, replacement standards and protocols having the same or similar functions as those disclosed herein are considered equivalents thereof.

[0095] A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a standalone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.

[0096] The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit).

[0097] As used in this application, the term "circuitry" or "circuit" refers to all of the following: (a)hardware-only circuit implementations (such as implementations in only analog and / or digital circuitry) and (b) to combinations of circuits and software (and / or firmware), such as (as applicable): (i) to a combination of processor(s) or (ii) to portions of processor(s) / software (including digital signal processor(s)), software, and memory(ies) that work together to cause an apparatus, such as a mobile phone or server, to perform various functions) and (c) to circuits, such as a microprocessor(s) or a portion of a microprocessor(s), that require software or firmware for operation, even if the software or firmware is not physically present.

[0098] This definition of "circuitry" applies to all uses of this term in this application, including in any claims. As a further example, as used in this application, the term "circuitry"would also cover an implementation of merely a processor (or multiple processors) or portion of a processor and its (or their) accompanying software and / or firmware. The term "circuitry" would also cover, for example and if applicable to the particular claim element, a baseband integrated circuit or applications processor integrated circuit for a mobile phone or a similar integrated circuit in server, a cellular network device, or other network device.

[0099] Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and anyone or more processors of any digital computer. The processor may receive instructions and data from a read only memory or a random-access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. The computer may also include or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio player, a Global Positioning System (GPS) receiver, to name just a few. Computer readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including by way of example semiconductor memory devices, e.g., E PROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto optical disks; and CD ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

[0100] To provide for interaction with a user, embodiments of the subject matter described in this specification can be implemented on a device having a display, e.g., a CRT (cathode ray tube), LCD (liquid crystal display), or LED (light emitting diode) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactilefeedback; and input from the user can be received in any form, including acoustic, speech, or tactile input.

[0101] Embodiments of the subject matter described in this specification can be implemented in a computing system that includes a back end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network ("LAN") and a wide area network ("WAN"), e.g., the Internet.

[0102] The computing system can include clients and servers. A client and server may be remote from each other and may interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship with each other.

[0103] One or more embodiments of the disclosure may be referred to herein, individually and / or collectively, by the term "invention" merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, are apparent to those of skill in the art upon reviewing the description.

[0104] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0105] As used herein, "for example," "for instance," "such as," or "including" are meant to introduce examples that further clarify more general subject matter. Unless otherwiseexpressly indicated, such examples are provided only as an aid for understanding embodiments illustrated in the present disclosure and are not meant to be limiting in any fashion. Nor do these phrases indicate any kind of preference for the disclosed embodiment.

[0106] The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.

[0107] It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the disclosure. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the disclosure.

Claims

CLAIMS1. An electrochemical plant comprising: a power supply section comprising a plurality of power supply modules positioned in a linear arrangement; an electrochemical stack section comprising a plurality of electrolysis modules positioned in a linear arrangement adjacent to and connected with the plurality of power supply modules; a process equipment section comprising a plurality of processing modules positioned in a linear arrangement adjacent to and connected with the plurality of electrolysis modules and / or the plurality of power supply modules; and a cooling section comprising a plurality of cooling modules positioned in a linear arrangement adjacent to and connected with one or more of the plurality of power supply modules, the plurality of electrolysis modules, or the plurality of processing modules, wherein each module of the plurality of power supply modules, the plurality of electrolysis modules, the plurality of processing modules, and the plurality of cooling modules is configured to be manufactured off-site and transported to a location of the electrochemical plant for installation and connection with one or more additional modules of the plurality of power supply modules, the plurality of electrolysis modules, the plurality of processing modules, and the plurality of cooling modules.

2. The electrochemical plant of claim 1, wherein a processing capacity of the electrochemical plant is configured to be expanded by an addition of at least one additional power supply module, at least one additional electrolysis module, at least one additional processing module, at least one additional cooling module, or a combination thereof, and wherein the at least one additional power supply module, the at least one additional electrolysis module, the at least one additional processing module, and / or the at least one additional cooling module is added at an end of the respective linear arrangement therein extending the respective linear arrangement of the plurality of power supply modules, the plurality of electrolysis modules, the plurality of processing modules, or the plurality of cooling modules.

3. The electrochemical plant of claim 1, wherein each power supply module comprises one or more medium voltage transformers, one or more AC-to-DC power converters, and one or more rectifiers configured to provide power to the plurality of electrolysis modules.

4. The electrochemical plant of claim 1, wherein the power supply section further comprises a power distribution center positioned between two power supply modules in the linear arrangement of the plurality of power supply modules, and wherein the power distribution center comprises a motor control center, a process logic controller, and an operator station.

5. The electrochemical plant of claim 1, wherein each power supply module of the plurality of power supply modules is connected to a same input source of power.

6. The electrochemical plant of claim 1, wherein each electrolysis module comprises a plurality of electrochemical stacks.

7. The electrochemical plant of claim 6, wherein the plurality of electrochemical stacks comprises at least 4 electrochemical stacks connected via a same anode inlet water supply and a same anode outlet water supply.

8. The electrochemical plant of claim 6, wherein each electrochemical stack comprises a plurality of electrochemical cells, and wherein each electrochemical cell within a respective electrochemical stack is configured to operate with 200 mV or less of pure resistive loss when operating at a current density of at least 3 Amps / cm2.

9. The electrochemical plant of claim 6, wherein each electrochemical stack of the plurality of electrochemical stacks is positioned at least 1 meter above a ground of the electrochemical plant, andwherein process piping connected to the plurality of electrochemical stacks is configured to pass between the ground and the plurality of electrochemical stacks.

10. The electrochemical plant of claim 9, wherein the process piping comprises a plurality of isolation valves positioned between two or more adjacent electrolysis modules, and wherein the plurality of isolation valves is configured to isolate or shut-off fluid flow to and from at least one electrolysis module to reduce a processing capacity of the electrochemical plant.

11. The electrochemical plant of claim 9, wherein each electrolysis module comprises a barrier positioned between the process piping and the ground, therein reducing an amount of hazardous area within the electrochemical plant.

12. The electrochemical plant of claim 1, wherein one or more processing modules of the plurality of processing modules comprises an anode gas separation module, a cathode gas separation module, a hydrogen product processing module, a feed water treatment module, and / or a process water heat exchange and pumping module.

13. The electrochemical plant of claim 12, wherein an anode gas separator in the anode gas separation module has a capacity of at least 12,000 liters, and a cathode gas separator in the cathode gas separation module has a volume or capacity of at least 3,500 liters.

14. The electrochemical plant of claim 1, wherein each cooling module comprises a plurality of dry or wet coolers configured to reject waste heat generated by the plurality of electrolysis modules to a surrounding environment.

15. The electrochemical plant of claim 14, wherein the plurality of dry or wet coolers are connected in parallel through a single manifold and configured to cool one or more process streams of at least one electrolysis module of the plurality of electrolysis modules.

16. The electrochemical plant of claim 1, wherein the electrochemical plant comprises openings between adjacent power supply modules, an opening between the plurality of electrolysis modules and the plurality of processing modules, and an opening between the plurality of processing modules and the plurality of cooling modules, and wherein each respective opening is at least 3 meters wide.

17. The electrochemical plant of claim 1, wherein a hazardous area of the electrochemical plant is limited to less than 33% of a total plant area.

18. The electrochemical plant of any of claims 1-17, wherein the electrochemical plant is configured to produce at least 10,000 kg / day of hydrogen gas.

19. The electrochemical plant of claim 18, wherein the hydrogen gas has a purity of at least 98%.

20. The electrochemical plant of claim 18, wherein the hydrogen gas is configured to be supplied to a customer at a pressure of at least 20 atm.

21. The electrochemical plant of claim 1, wherein a misalignment between two modules of the plurality of power supply modules, the plurality of electrolysis modules, the plurality of processing modules, and the plurality of cooling modules that are configured to be connected to each other at the location of the electrochemical plant is corrected or averted through a use of flexible couplings, shims, long pipe lengths, and / or laser scanning of the location of the electrochemical plant.

22. The electrochemical plant of any of claims 1-17, wherein the electrochemical plant is configured to generate at least 25 megawatts of power.

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