Device and method for maintaining gas pressure in electrolyser using electric generator configured for capturing kinetic energy of electrolysis products

Abstract

FIELD: electricity generation.SUBSTANCE: invention relates to a device for capturing energy for generating electrical energy from gases formed during electrolysis. The device includes: a rotating element located downstream from the gas outlet of the electrolyser and mechanically connected to an electric generator, wherein the rotating element is configured to rotate in response to gas released from the electrolyser, wherein the rotation causes the generation of electric power by the electric generator; a pressure regulator configured to control the pressure of at least one gaseous product during electrolysis and located between the gas outlet and the rotating element; a power regulator configured to organizationally control the power from the electric generator and at least one external power source; a control circuit configured to monitor the gas pressure of at least one gaseous product inside the electrolyser and to control the rotation speed of the rotating element; and a transmission having a plurality of available gear ratios, wherein the transmission is located between the rotating element and the electric generator, wherein the control circuit is also configured to select a gear ratio from a plurality of available gear ratios and to apply the selected gear ratio to the transmission. The invention also relates to a method.EFFECT: greater energy efficiency of the system.18 cl, 4 dwg

Description

Link to a related application

[0001] This application claims the priority and benefit of U.S. Provisional Patent Application No. 63 / 271,755, filed October 26, 2021, the contents and disclosure of which are incorporated herein by reference in their entirety. State of the art

[0002] The present invention relates to the use of a generator capable of generating electrical energy from compressed gases for maintaining gas pressure in an electrolysis system. In particular, the invention can be integrated into a hydrogen generation system capable of producing hydrogen gas and oxygen gas from fresh water or seawater, either at ground level or submerged in a body of water. The system can be capable of providing electrolysis of fresh or seawater. Disclosure of the essence of the invention

[0003] Climate change is one of the greatest threats facing the world today. Extreme weather events such as floods, hurricanes, fires, and heat waves, among others, are becoming increasingly common as the atmosphere continues to be polluted by greenhouse gases produced by the burning of fossil fuels. Therefore, the planet must be provided with alternatives to polluting energy sources, and high-emitting countries must abandon the use of polluting fossil fuels.

[0004] Achieve net zero emissions by mid-to-late In the 21st century, carbon-free fuels and energy sources have become a priority for both developing and developed countries. An integral part of these ambitious goals are renewable energy sources such as solar and wind power. However, the electricity produced cannot always be stored and accessed when needed, and these energy sources alone cannot quickly, efficiently, and affordably replace fossil fuels.

[0005] Hydrogen is a fuel that stores energy for later use. Hydrogen has many advantages, including its lack of pollution (its byproduct is water), its ability to be compressed into an energy-dense fuel, and its potential to make energy affordable worldwide. Furthermore, hydrogen can store energy as an alternative to large batteries or other energy storage methods. The development of a strong hydrogen economy will free up countries currently dependent on fossil fuels, and when integrated with renewable energy sources, it will significantly reduce the carbon footprint of any country using the fuel.

[0006] Current hydrogen production technologies produce greenhouse gases because most hydrogen is produced using carbon-based feedstocks or requires very pure water (an increasingly scarce resource), both of which are inefficient at converting external energy into hydrogen. Most hydrogen produced in the United States is produced using steam methane reforming, a process that uses a carbon-based fuel—methane—and produces carbon dioxide, a greenhouse gas. On the other hand, processes that do not produce greenhouse gases, such as pure water electrolysis, are limited in their efficiency at converting electricity into hydrogen and require additional energy to purify the feedstock water. Efficiency decreases even further when this hydrogen must be compressed, stored, and delivered to consumers. Harnessing the kinetic energy of the gases produced by the electrolyzer will increase the efficiency of the entire system.

[0007] An underwater hydrogen electrolysis system capable of electrolyzing fresh or seawater will solve many of the existing problems associated with hydrogen production. The underwater system will not produce greenhouse gases during operation, will not necessarily require clean water, and will increase its operational efficiency by capturing the kinetic energy of the resulting gases. Such a system will be able to electrolyze fresh or seawater.

[0008] Therefore, in the field of electrolysis, there is a need for a generator capable of generating electricity from the gases produced by the electrolyzer, especially if such gases are initially produced at high pressure. Such a system would be able to generate its own electricity, ensuring greater energy efficiency.

[0009] The present invention comprises a generator used in an electrolysis system to improve the energy efficiency of the system by utilizing the energy of the high-pressure hydrogen and / or oxygen gases produced. The generator comprises a device that generates energy from the differential pressures created as a byproduct of water electrolysis or from the differential pressures created as a byproduct of high-pressure water electrolysis. The electrolyzer, located in a chamber deep in water, will have its anode section connected to one pipe and its cathode section connected to a second pipe. The pipes will extend upward beyond the chamber containing the electrolyzer through watertight seals and will transport the oxygen and hydrogen byproducts created during the electrolysis process to the surface of the water.

[0010] The process of water electrolysis, contained in a chamber or a pressurized vessel, will separately produce hydrogen (H2) and oxygen (O2) gases, which will either be dissolved in the aqueous solution or solutions used for the electrolysis process or will separately produce these gases in their natural gaseous forms. In either case, differential pressures will be created as a byproduct of the electrolysis process due to the formation of hydrogen (H2) and oxygen (O2) gases of lower density or aqueous solutions at the electrolysis cathode or anode relative to the density of the adjacent aqueous solution or solutions in the electrolysis chamber.The difference in density will create a difference in the pressure of the aqueous solution or gas, which will cause the lower density hydrogen (H2) and oxygen (O2) aqueous solutions or gases to flow out of the electrolysis chamber, provided that the chamber has an outlet pipe or pipes and the opposite end of the pipe or pipes is at a lower pressure than the pressure in the chamber.

[0011] Additional gas pressure differentials may be observed if electrolysis is carried out in a high-pressure environment, such as the seabed, where the gases produced are slightly larger than the high-pressure environment. Considering that gases (H2 and O2) are produced with minimal gravitational influence on gas pressure from the bottom (e.g. 10,000 ft) to the top (sea level) in the connected pipeline, it can be inferred that the system will provide 300 bar at sea level (approximately 1 bar). By capturing the energy from the H2 and O2 gas pressure, it has been calculated that such a system could provide up to 25% of the electrolyzer's electrical power requirement. This is based on compressor power consumption (inversely related to the gas turbine) at a very conservative system efficiency of 50%. At 300 bar, approximately 35 kW can be achieved for a gas flow of 30 Nm3 / h, or approximately 6 kW / kg H2. With a proportionally equivalent volume of O2 gas, from which an additional 3 kW is estimated, a total of 9 kW per kg of H2 produced is calculated.

[0012] Energy in the form of electrical energy is captured from the product of aqueous solutions of hydrogen (H2) and oxygen (O2) or gases passing through a pipe or pipes by incorporating a turbogenerator or multiple turbogenerators in the pipe or pipes, or at either end of the pipe or pipes. One or more generators may be located in one or both pipes, and if multiple generators are present, they will be arranged in series within the pipes. The generators may be driven by rotors that are turned by the hydrogen and oxygen moving up the pipes. Before each generator, the pipe may narrow to restrict the gas flow and increase the force of the gas turning the rotors and driving the generators. In this case, the pipe diameter will widen again after each generator.

[0013] This document describes systems and methods for monitoring gas pressure using a generator in an electrolysis system and maintaining gas pressure using an electric generator for kinetic energy capture to improve the energy efficiency of the system by using the energy of compressed hydrogen and / or oxygen gases as they are produced by the electrolyzer. The gas pressure of at least one gaseous product is monitored during electrolysis at a gas outlet of the electrolyzer. If the gas pressure reaches a threshold value, at least one gaseous product is released from the gas outlet. The kinetic energy of the released gas is captured using a rotating element located downstream of the gas outlet. The rotating element, which can be, for example, a fan or a turbine, is mechanically connected to the electric generator.The rotating element is configured to rotate in response to gas released from the electrolyzer, and this rotation causes the electric generator to generate electricity. The power management system manages power from the electric generator and at least one external power source to supply the electrolyzer with electricity. Power can be supplied to the electrolyzer from more than one power source simultaneously.

[0014] In some embodiments, a transmission is located between the rotating element and the electric generator. For example, the rotating element is mechanically connected to the transmission input shaft, and the generator is driven by the transmission output shaft. A transmission gear ratio can be selected and applied to the transmission to control the turbine speed and / or the amount of electricity generated by the electric generator. Controlling the turbine speed can also be used to control and maintain pressure in the electrolyzer.

[0015] In some embodiments, electrical energy from an electric generator is transferred to a battery pack. The battery pack is then charged using electricity from the electric generator. The battery pack can be used as an additional power source for the electrolyzer.

[0016] Additional rotating elements (e.g., fans or turbines) can be located downstream of each other. Each rotating element can be connected to a separate electric generator. The configuration of each rotating element, such as the blade pitch, can be controlled to increase or decrease the rotational speed of each rotating element. Brief description of the drawings

[0017] The above and other objects and advantages of the present invention will become apparent from a consideration of the following detailed description taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

[0018] Fig. 1 shows an example of a device for generating electrical energy from differential pressures of by-products of water electrolysis according to some embodiments of the invention;

[0019] Fig. 2 is a block diagram showing the components and interactions therebetween of an apparatus for generating electrical energy from differential pressures of by-products of water electrolysis in accordance with some embodiments of the present invention;

[0020] Fig. 3 is a flow chart showing an exemplary process for maintaining gas pressure in an electrolyzer by controlling a gas outlet and the speed of rotation of a turbine through which gases discharged from the outlet will flow, in accordance with some embodiments of the present invention; and

[0021] Fig. 4 is a block diagram representing an illustrative process for monitoring and controlling electrical power flows in an electrolyzer in accordance with some embodiments of the present invention. Implementation of the invention

[0022] Fig. 1 shows an example of a device for generating electrical energy from differential pressures of by-products of water electrolysis according to some embodiments of the present invention. An electrolyzer 102 may be located in a high-pressure chamber or other gas-tight vessel 100. The vessel 100 may be located in a freshwater or saltwater environment and may be placed at any suitable depth of water. Water may be drawn into the vessel 100 or otherwise introduced into the vessel 100. When water contacts the electrolyzer 102 or flows through the electrolyzer 102, hydrogen (H2) and oxygen (O2) are formed. At least one gas outlet pipe 104 may be used to direct these gaseous products from the vessel 100 to another location.The hydrogen product can be sent to a hydrogen storage tank or compressor unit for subsequent use to power hydrogen fuel systems or produce hydrogen fuel cells.

[0023] Oxygen gas that does not require separate storage for later use can be directed through gas outlet pipe 104 to pressure valve 106. Pressure valve 106 can be calibrated or electronically controlled to ensure gas release only after the gas reaches a certain pressure. When this pressure is reached, pressure valve 106 opens to allow gas to pass through. Pressure valve 106 can remain open for a fixed time or until a set minimum pressure is reached, after which it closes again and allows the gas pressure to build up. Building up the pressure ensures that the electrolyzer continues to operate in an optimal environment by equalizing the water pressure at the electrolyzer inlet. This prevents damage to the electrolyzer from water forcing through the electrolyzer's separating membrane, which is a common component of any electrolyzer.The accumulation of high pressure gas has a negative effect on the deep water pressure at the entrance.

[0024] After passing through the pressure valve 106, the gas is directed into the turbine 108. When the gas flows through the turbine 108, the gas pressure rotates the turbine 108, which causes the shaft 110 to rotate. The gas then exits the turbine 112 into a lower pressure environment (for example, atmospheric pressure). The shaft 110 can be an input shaft of a transmission 114, which can be selectively adapted to control the rotation speed of the output shaft 116. The output shaft 116 is connected to an electric generator or an alternator 118. The rotation of the output shaft 116 drives the electric generator 118 to generate electricity. In some embodiments, the shaft 110 is connected directly to the electric generator 118. The electricity generated by the electric generator 118 can be transmitted through an electrical connection 120 to a battery pack 122 for storage.Electric power may be transferred 124 from electric generator 118 to electrolyzer 102 to drive additional electrolysis, or may be transferred 126 from battery pack 122. Additional electric power may be transferred 128 from another source, such as power grid 130, to electrolyzer 102 to supplement the electric power provided by electric generator 118 or battery pack 122.

[0025] In some embodiments, additional fans or turbines may be located downstream of turbine 108, with each additional fan or turbine connected to a separate electric generator. All electric generators may then be connected to battery pack 122 and / or electrolyzer 100.

[0026] Fig. 2 is a block diagram showing the components and the interaction between them of a device for creating electrical energy from differential pressures of by-products of water electrolysis in accordance with some embodiments of the present invention; Electrolyzer 200 produces compressed gas, which flows 202 from the electrolyzer 200 to accumulate in a compressed gas manifold 204. A pressure sensor and a controller 206 monitor and control the gas pressure in the compressed gas manifold 204 for both system safety and optimization. The pressure sensor and the controller monitor 208 the pressure of at least one gas in the compressed gas manifold 204. The gases exert pressure 210 on the pressure sensor and the controller 206. The pressure sensor and the controller 206 transmit 212 a signal to the control module 214. The control module 214 may be a processor or a controller of another type.The control module 214 may be based on any suitable processing circuit and comprises control circuits and memory circuits, which may be located on a single integrated circuit or may be discrete components. As mentioned in this document, the processing circuit shall be understood to be a circuit based on one or more microprocessors, microcontrollers, digital signal processors, programmable logic devices, field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), etc., and may include a multi-core processor (e.g., dual-core, quad-core, six-core, or any suitable number of cores).In some embodiments, the processing circuitry may be distributed across multiple individual processors or processing units, such as multiple processors of the same type (e.g., two Intel Core i7 processors) or multiple different processors (e.g., an Intel Core i5 processor and an Intel Core i7 processor).

[0027] The control module 214 receives a signal from the pressure sensor and the regulator 206 and compares the current pressure in the compressed gas manifold 204 with the threshold pressure. The threshold pressure can be calibrated based on the materials and / or design of the electrolyzer 200 or the compressed gas manifold 204, in case the compressed gas manifold 204 is physically separated from the electrolyzer 200. In some embodiments, the compressed gas manifold 204 is an integral part of the electrolyzer 200 and can be located on or combined with a gas outlet through which gaseous products of electrolysis can be released from the electrolyzer 200. If the control module 214 determines that the current pressure has reached or exceeded the threshold pressure, the control module 214 transmits 216 a signal instructing the pressure sensor and the regulator 206 to release gas from the compressed gas manifold 204.For example, the pressure sensor and controller 206 may comprise a solenoid valve that can be opened in response to a signal received from the control module 214. In some embodiments of the present invention, the pressure sensor and controller 206 may not rely on the control module 214 to release gas when a pressure threshold is reached or exceeded. This may be for safety reasons, since the control module 214 may be susceptible to electronic interference, circuit degradation, or other factors that may lead to a failure of the control module 214 or prevent the command from the control module 214 from reaching the pressure sensor and controller 206.

[0028] After discharge, the compressed gas enters 218 directly into the turbine 220, from which it is then discharged into an atmosphere with a lower pressure. The force used to rotate the turbine or fan is largely influenced by the pressure difference between the compressed gas entering the turbine or fan and the atmospheric pressure to which the gas will subsequently be discharged. When the compressed gas flows through the turbine 220, the turbine 220 rotates. The rotational energy of the turbine 220 is transmitted 222 through a mechanical connection to the electric generator 224, where the rotational energy is used to generate electricity. In some embodiments, the turbine 220 reports 226 its rotational speed (for example, revolutions per minute) to the control module 214. To obtain the required amount of electricity in the electric generator 224, the control module 214 can increase or decrease the rotational speed of the turbine 220.For example, the angle or inclination of one or more blades or vanes of the turbine 220 relative to the plane of rotation of the turbine can be adjustable. The control module 214 can instruct 228 the turbine 220 to adjust the inclination of the blades or vanes to increase or decrease the rotation speed of the turbine 220. For example, if the compressed gas is at a higher pressure, the inclination of the blades or vanes can be adjusted to be shallower so as not to drive the turbine, while the inclination can be adjusted to be steeper when the compressed gas is at a lower pressure in order to achieve maximum rotation. In some embodiments, the threshold pressure can be adjusted by the control module 214 to achieve the desired rotation speed of the turbine 220 when gas passes through it.

[0029] In some embodiments, turbine 220 does not have a direct mechanical connection with electric generator 224, but rather has a mechanical connection with the input shaft of the transmission box. Rotational energy is then transmitted 230 from turbine 220 to transmission 232. Control module 214 can select and apply a gear ratio to transmission 232 to increase or decrease the rotational speed of the output shaft of transmission 232, which is then connected to electric generator 224. Transmission 232 can have a fixed set of available gear ratios or can be a continuously variable transmission, which allows control module 214 to more accurately select and apply gear ratios to transmission 232.

[0030] In some embodiments of the present invention, the electric generator 224 provides a torque load to the turbine 220, which can subsequently be controlled to influence the pressure of the compressed gas entering the turbine 220, and which is controlled by the pressure sensor and the controller 206. The torque load of the electric generator 224 is influenced by the electrical load applied to it from the electrolyzer 200, through the electrical connection 260 between the electrolyzer 200 and the electrolyzer power controller 238 and transmitted through 240. An optional additional electrical load 242 for charging the battery pack 244 through the battery pack charger 246 and the electrical connection 248 can also influence the electrical load.

[0031] The electrolyzer power controller 238 may include its own processing circuit. Similar to the control module 214, the processing circuit of the electrolyzer power controller 238 may be based on any suitable processing circuit and includes control circuits and memory circuits, which may be located on a single integrated circuit or may be discrete components.

[0032] The electrolyzer power controller 238 monitors and controls the requirements for the working electrical load of the electrolyzer 200. It consumes 240 electrical energy directly from the electric generator 224, consumes 254 electrical energy from the battery pack 244 and consumes 256 electrical energy from additional power 258 (for example, a public power grid, a solar battery, a wind turbine, etc.) depending on the availability of electrical energy from each source, and the load command of the electric generator 224 transmitted via the bidirectional data channel 252 from the control module 214. Thus, the control module 214 monitors the mechanical loads of the system and carries out organizational control over them, while the electrolyzer power controller 238 monitors the electrical loads of the system and carries out organizational control over them.The electrolyzer power controller 238 can simultaneously consume electrical energy from more than one source. For example, the electric generator 224 or the battery pack 244 may not be able to provide all the electrical energy needed to operate the electrolyzer 200. Therefore, the electrolyzer power controller 238 consumes energy from both the electric generator 224 (or the battery pack 244) and the additional power 258 simultaneously to provide the electrolyzer 200 with the necessary electrical energy. The electrolyzer power controller 238 then transfers 260 electrical energy to the electrolyzer 200.

[0033] The electrolyzer power controller 238 is connected to the control module 214, the electric generator 224, the additional power source 258 and the optional battery pack charger 246 and the battery pack 244 associated with it. The electrolyzer power controller 238 supplies the electrolyzer 200 as needed and receives electric power from the electric generator 224, the optional battery pack 244 and the additional power source 258 in the specified order of priority. The electrolyzer power controller 238 also controls the electrical load requirements for the electric generator 224, which are requested by the control module 214, by receiving electric power directly from the electric generator 224 or by changing the charging load of the battery pack charger 246.

[0034] The control module 214 can give a command to the power controller 238 of the electrolyzer 250 to increase or decrease the torque load on the turbine 222. In some embodiments, the control module 214 carries out organizational control of the compressed gas pressure and maintains the pressure of the compressed gas by monitoring the pressure in the system and adjusting the requests of the turbine 222 for the torque load to the power controller 242 of the electrolyzer, which subsequently regulates the electric load on the electric generator 226. In the event that the pressure parameters are exceeded for the compressed gas, and they cannot be further influenced by reducing the torque load for the electric generator 226, the optional gear ratio of the transmission 234 or the optional blades of the turbine 222 with variable pitch, then the control module 214 sends signals to the pressure sensor and the controller 206 to reset the pressure.

[0035] The control module 214 can also carry out organizational control of the rotation speed of the turbine 222 and maintain the rotation speed of the turbine 222 by monitoring the revolutions per minute and adjusting either the optional transmission ratio 234, the optional variable-tilt blades of the turbine 222, or the torque load requests to the electrolyzer power controller 242, which subsequently regulates the electrical loads on the electric generator 226. In the event that the system parameters are exceeded for the rotation speed of the turbine, and they cannot be further influenced by the torque load for the electric generator 226, the optional transmission ratio 234 or the optional variable-tilt blades of the turbine 222, then the control module 214 sends signals to the pressure sensor and the controller 206 to reset the pressure.

[0036] The control module 214 carries out organizational control of the system to achieve target compressed gas pressures that are greater than or close to the pressure of the environment in which the electrolyzer is located, in order to effectively ensure that the various pressures experienced by the electrolyzer, its internal components and separation membranes do not exceed the design parameters.

[0037] Fig. 3 shows a flow chart representing an exemplary process 300 for maintaining gas pressure in an electrolyzer by controlling a gas outlet and the speed of rotation of a turbine through which gases discharged from the outlet will flow, in accordance with some embodiments of the present invention. The process 300 can be performed by the control module 214. Furthermore, one or more actions of the process 300 can be included in or combined with one or more actions of any other process or embodiment described herein.

[0038] In step 302, control module 214 monitors the gas pressure of at least one gaseous product during electrolysis at the gas outlet of the electrolyzer. For example, control module 214 may receive signals for a gas pressure sensor (e.g., pressure sensor and controller 206). The signals received from the gas pressure sensor may be an analog signal (e.g., voltage level) or a digital signal (e.g., binary message). Control module 214 may process the signal to determine the gas pressure at the gas outlet.

[0039] In step 304, the control module 214 sets the value of the variable P to the current pressure determined based on the signal from the pressure sensor, expressed in bars, atmospheres, torr, pascals, pounds per square inch, or any other suitable pressure unit. In some embodiments, the pressure sensor may be designed or calibrated to report pressure readings in one unit of measurement, which the control module 214 can convert to another unit of measurement. The control module 214 also initializes the variable R P , representing the threshold pressure range. For example, R P can be an array or other data structure representing the minimum pressure and maximum pressure. The minimum pressure might be 300 bar, and the maximum 500 bar.

[0040] In step 306, the control module 214 determines whether the current pressure P is above the threshold range R Ppressure. For example, control module 214 compares the value P with the maximum R P to determine whether P exceeds R P. If so (Yes in step 306), then in step 308, control module 214 releases gas to reduce the pressure. For example, control module 214 may signal a gas valve, such as a solenoid valve, to open and remain open until the pressure is reduced to the R range. P threshold pressure. In some embodiments, this action should be performed directly by the pressure sensor and controller 206 to avoid processor delay or failure during a critical overpressure scenario. After the gas is released, processing returns to step 302, where control module 214 continues to monitor the gas pressure.

[0041] If the current pressure P does not exceed R P(No at step 306), then at step 310 the control module 214 determines whether P is below the threshold range R P For example, control module 214 compares the value P with the minimum R P to determine whether P is below R P. If this is the case (Yes on 310), then processing returns to 302, where the control module continues monitoring the gas pressure. If P is not below R P (No on 310), then P is defined as being within the threshold pressure range R P At step 312, control module 214 alternately releases at least one gaseous product from the gas outlet. For example, the control module may open the gas outlet variable to allow a certain volume of gas to exit or to allow gas to exit at a certain rate. The gas passes through the outlet and into an outlet pipe leading to the turbine.

[0042] At step 314, control module 214 monitors the turbine speed. For example, the turbine may include a tachometer or other sensor that allows the control module to determine the RPM at which the turbine is rotating. At step 316, control module 214 sets the value of variable S to the current turbine speed. Control module 214 also initializes variable R. S , representing the threshold range of turbine rotation speed. At step 318, the control module determines whether the current turbine rotation speed S exceeds the threshold speed range R S For example, control module 214 compares the value S with the maximum value R S .

[0043] If S exceeds R S("Yes" in step 318), or after releasing the gas in step 308, in step 320, the control module 214 determines whether the transmission and / or the turbine blade pitch are configured for the lowest rotation speed. For example, the control module 214 may determine the gear ratio currently applied in the transmission and compare it with the available gear ratio that will result in the lowest rotation speed of the turbine. The control module 214 may also determine the pitch angle of the turbine blades and compare it with the available pitch angle that will result in the lowest rotation speed of the turbine. If the transmission gear ratio or the pitch angle of the turbine blades can be adjusted to result in a lower rotation speed ("No" in step 320), then in step 322 the control module 214 changes the transmission gear ratio and / or the pitch angle of the turbine blades to a configuration that reduces the rotation speed of the turbine.Processing then returns to step 314 where control module 214 continues to monitor the turbine speed.

[0044] If the transmission and blade pitch are already set to the lowest turbine speed ("Yes" in step 320), then at step 324, control module 214 signals the electrolyzer power controller to increase the load on the electric generator. Increasing the load on the electric generator will slow the rotation of the electric generator rotor, to which the turbine output shaft is connected, either directly or through the transmission. Processing then returns to step 314, where control module 214 continues to monitor the turbine speed.

[0045] If ​​the current turbine speed S does not exceed R S (No at step 318), then at step 326 the control module 214 determines whether S is below R S . For example, control module 214 may compare the value of S with the minimum of R S If S is not below the minimum RS (No on 326), then the turbine speed is within the threshold speed range and processing returns to step 314 where control module 214 continues to monitor the turbine speed.

[0046] If the turbine speed is below R S("Yes" in step 326), then in step 328, the control module 214 determines whether the transmission gear ratio or the turbine blade pitch angle is configured for the highest possible rotational speed of the turbine. For example, the control module 214 may determine the gear ratio currently applied to the transmission and compare it with the available gear ratio that will result in the highest rotational speed. The control module 214 may also determine the current turbine blade pitch angle and compare it with the available pitch angle that will result in the highest rotational speed of the turbine. If the transmission gear ratio or the turbine blade pitch angle can be adjusted to increase the rotational speed of the turbine ("No" in step 328), then in step 330, the control module 214 changes the transmission gear ratio and / or the turbine blade pitch angle to a configuration that will result in a higher rotational speed of the turbine.Processing then returns to step 314 where the control circuit continues to control the turbine speed.

[0047] If the transmission gear ratio and turbine blade pitch are already set to the highest rotation speed ("Yes" in step 328), then at step 330, control module 214 signals the electrolyzer power controller to reduce the load on the electric generator, thereby increasing the speed at which the turbine output shaft can rotate. Processing then returns to step 314, where control module 214 continues to monitor the turbine rotation speed.

[0048] In some embodiments, control module 214 continuously monitors the gas pressure in the gas outlet. After gas is released from the gas outlet into the turbine, control module 214 can monitor the pressure in the gas outlet and close the outlet when the pressure reaches a minimum level. This allows the gas pressure to build up again to a point where the gas outlet can be used to efficiently rotate the turbine.

[0049] The actions or descriptions shown in Fig. 3 may be used with any other embodiment of the present invention. Furthermore, the actions and descriptions described with reference to Fig. 3 may be performed in any suitable alternative order or in parallel for additional purposes of the present invention.

[0050] Fig. 4 shows a flow chart representing an exemplary process 400 for monitoring and controlling electric power flows in an electrolytic cell in accordance with some embodiments of the present invention. The process 400 can be performed by the electrolytic cell power controller 238. Furthermore, one or more actions of the method 400 can be included in or combined with one or more actions of any other process or embodiment described herein.

[0051] At step 402, the electrolyzer power controller 238 controls the electrolyzer power requirements in accordance with the operating settings. The electrolyzer may be configured by an operator or an operational control processor or other circuit to meet certain performance indicators, including the volume of gas produced per unit of time, the consumption of electricity per unit of time, or other indicators. To meet the performance indicators, the electrolyzer may require a different amount of power. At step 404, the electrolyzer power controller 238 determines whether the electrolyzer power requirements are met. For example, the electrolyzer power controller 238 may detect, monitor, or otherwise determine the consumption of electric current from the electrolyzer and compare it with the amount of electric current supplied by the electrolyzer power controller 238 to the electrolyzer from one or more power sources.If the power requirement is satisfied (Yes in step 404), then processing returns to step 402 where the electrolyzer power controller 238 continues to control the electrolyzer power requirements.

[0052] In some embodiments, the electrolyzer power controller 238 also determines in step 406 whether the load requirement of the control module 214 is met. For example, the electrolyzer power controller 238 can communicate with the control module 214 and receive signals indicating whether the load requirement is met or not. For example, the control module 214 can determine that a reduced electrical load is required on the electric generator. If this is the case ("Yes" in step 406), then the electrolyzer power controller continues to control the power requirements of the electrolyzer. If the load requirements of the control module are not met ("No" in step 406) or if the power requirements of the electrolyzer are met ("No" in step 404), then in step 406 the electrolyzer power controller 238 determines whether the electrolyzer requires more or less power.For example, the electrolyzer power controller 238 may determine whether the amount of current consumed by the electrolyzer exceeds the amount of current provided by the electrolyzer power controller 238, or if the electrolyzer power controller 238 provides more electric current than is consumed by the electrolyzer.

[0053] If less current is currently supplied than required by the electrolyzer ("Less" in step 408), then in step 410 the electrolyzer power controller 238 determines whether the load requirement on the additional power source is set at the minimum load level. For example, the electrolyzer power controller 238 can be configured to receive power from an electric generator connected to a turbine, a battery pack, and at least one additional power source, such as a solar panel or a public power grid. The electrolyzer power controller can be configured to receive power from each of these sources in descending order of preference, with the additional power source being the least preferred. Thus, if less power is required, the electrolyzer power controller 238 first determines whether power is consumed from the additional power source.If so, the power drawn from this source can be reduced. Consequently, the load requirement is not minimal ("No" in step 410), and in step 412, the electrolyzer power controller 238 reduces the direct load requirement on the auxiliary power source. This results in less power being drawn from the auxiliary power source and, consequently, less power being supplied to the electrolyzer. After reducing the load requirement on the auxiliary power source, processing returns to step 402, where the electrolyzer power controller 238 continues to control the electrolyzer's power requirements.

[0054] If a further reduction in power is required, and the load requirement on the additional power source is already at a minimum ("Yes" in step 410), then in step 414 the electrolyzer power controller 238 determines whether the power consumption from the battery pack is set to a minimum. This can be accomplished using methods similar to the methods described above in connection with step 410. If the power consumption from the battery pack is not set to a minimum level ("No" in step 414), then in step 416 the electrolyzer power controller 238 reduces the power consumption from the battery pack, thereby reducing the amount of power available to the electrolyzer. Then, processing returns to step 402, where the electrolyzer power controller 238 continues to control the power requirements of the electrolyzer.

[0055] If a further reduction in power is required, and the load requirement for both the additional power source and the battery pack is already at a minimum ("Yes" in step 414), then in step 418 the electrolyzer power controller 238 determines whether the direct load per unit of power on the electric generator is set to a minimum. Again, this can be accomplished using methods similar to those described above in connection with step 410. If the direct load per unit of power on the electric generator is not minimum ("No" in step 418), then in step 420 the electrolyzer power controller 238 reduces the direct load requirement on the electric generator, thereby reducing the amount of power available to the electrolyzer.

[0056] If the direct load per unit of power on the electric generator is set to the minimum value ("Yes" in step 418), then in step 422, the electrolyzer power controller 238 generates an alarm to warn the electrolyzer operator that the amount of electric power available to the electrolyzer cannot be further reduced at the current time. Processing then returns to step 402, where the electrolyzer power controller continues to monitor the electrolyzer power requirements.

[0057] If more current is currently supplied than is required by the electrolyzer ("More" in step 408), then in step 424 the electrolyzer power controller 238 determines whether the maximum direct load on the electric generator is set. This can be accomplished using methods similar to the methods described above in connection with step 410. If the direct load on the electric generator is not maximum ("No" in step 424), then in step 426 the electrolyzer power controller 238 increases the direct load on the electric generator, thereby creating additional electric power available to the electrolyzer. The process then returns to step 402, where the electrolyzer power controller continues to monitor the power requirements of the electrolyzer.

[0058] If the direct load per unit of power on the electric generator is at the maximum ("Yes" in step 424), then in step 428 the electrolyzer power controller 238 determines whether the power consumption from charging the battery pack is set to the maximum. This can be accomplished using methods similar to the methods described above in connection with step 410. If the power consumption from the battery pack is not set to the maximum ("No" in step 428), then in step 430 the electrolyzer power controller 238 determines whether the battery pack charge exceeds the low voltage cutoff. For rechargeable batteries, it is necessary to maintain a minimum voltage in each cell for the battery to operate properly. Overcharging the batteries can cause damage to one or more cells. The electrolyzer power controller 238 can communicate with the battery pack charger to determine the voltage in each cell.If the charge is greater than the low voltage cutoff ("Yes" in step 430), then in step 432, the electrolyzer power controller 238 increases the battery pack's charge setting. This results in additional power being supplied to the electrolyzer. Processing then returns to step 402, where the electrolyzer power controller continues to monitor the electrolyzer's power requirements.

[0059] If the battery pack power consumption is already set to the maximum power consumption ("Yes" in step 428), and the battery pack charge is at or below the low voltage cutoff ("No" in step 430), then at step 434, the electrolyzer power controller 238 increases the forward load requirement by the additional power. This allows the electrolyzer to receive more power from the additional power source(s). Processing then returns to step 402, where the electrolyzer power controller 238 continues to control the electrolyzer power requirements.

[0060] Using the above steps, the electrolyzer power controller 238 continuously balances the power consumed by the electrolyzer from each of the available power sources. In some embodiments, the electrolyzer power controller 238 also continuously balances the use of electrical power generated by the electric generator. For example, the charging load of the battery pack can also be adjusted to provide more or less power available to the electrolyzer. In some cases, the battery pack charger can be configured to operate in various power consumption modes, such as a low-power mode, a short-term charge mode, or can charge a subset of the battery pack cells in the battery pack. In the maximum charge mode, the battery pack charger can simultaneously consume more current and / or charge more cells.If the battery pack's charging is not set to the maximum charging load, the battery pack charger increases the battery pack's charging setting. For example, the battery pack charger may operate in a higher power consumption mode. This draws additional power from the available power source, thereby reducing the power available to the electrolyzer. Similarly, to increase the power available to the electrolyzer, the battery pack charger may operate in a lower power consumption mode.

[0061] The actions or descriptions shown in Fig. 4 may be used with any other embodiment of the present invention. Furthermore, the actions and descriptions described with reference to Fig. 4 may be performed in any suitable alternative order or in parallel for additional purposes of the present invention.

[0062] The above descriptions are given to enable those skilled in the art to put the invention into practice, and the embodiments published herein merely illustrate the present device and do not limit the scope of the appended claims.

Claims

1. A device for capturing energy for generating electrical energy from gases formed during electrolysis, comprising: a rotating member located downstream of the gas outlet of the electrolyzer and mechanically connected to an electric generator, wherein the rotating member is configured to rotate in response to gas discharged from the electrolyzer, wherein the rotation causes the electric generator to generate electrical energy; a pressure regulator configured to control the pressure of at least one gaseous product during electrolysis and located between the gas outlet and the rotating element; a power regulator configured to control the power from an electric generator and at least one external power source in an organizational manner; a control circuit configured to monitoring the gas pressure of at least one gaseous product inside the electrolyzer and control of the rotation speed of the rotating element; and a transmission having a plurality of available gear ratios, wherein the transmission is located between the rotating element and the electric generator, wherein the control circuit is also designed with the possibility selecting a gear ratio from a set of available gear ratios and applying the selected gear ratio to the transmission.

2. The device according to claim 1, wherein the rotating element comprises a fan.

3. The device according to claim 1, wherein the rotating element comprises a turbine.

4. The device according to claim 1, in which the rotating element also includes a plurality of adjustable blades; and the control circuit is also configured to control the angle of the plurality of adjustable blades relative to a plane perpendicular to the axis of rotation of the rotating element.

5. The device according to claim 1, in which the power regulator is also configured to simultaneously transmit electrical energy from both the electric generator and from an external power source to the electrolyzer.

6. The device according to paragraph 1, also including: a battery pack comprising one or more batteries; and charger for battery pack.

7. The device according to claim 6, in which the power regulator is also configured to selectively transfer electrical energy from the electric generator to the battery pack charger or electrolyzer and selectively transfer electrical energy from at least one external power source to the battery pack charger or electrolyzer.

8. The device according to item 1, also including at least one additional rotating element located downstream of the rotating element and mechanically connected to an additional electric generator, wherein the additional electric generator is electrically connected in series with the said electric generator.

9. The device according to claim 8, wherein the control circuit is also configured to control at least one additional rotating element.

10. A method for capturing energy for generating electrical energy from gases formed during electrolysis, comprising: monitoring the gas pressure of at least one gaseous product during electrolysis at a gas outlet of the electrolyzer; in response to determining that the gas pressure of at least one gaseous product has reached a threshold pressure, releasing at least one gaseous product from a gas outlet; capturing kinetic energy of at least one gaseous product using a rotating element located downstream of the gas outlet and mechanically connected to an electric generator, wherein the rotating element is configured to rotate in response to gas discharged from the electrolyzer, wherein the rotation causes the electric generator to generate electrical energy; selecting a gear ratio of a transmission located between a rotating element and an electric generator, wherein the transmission has a plurality of available gear ratios; applying the selected gear ratio to the transmission; and organizational control of power from an electric generator and at least one external power source to provide the electrolyzer with electric power.

11. The method of claim 10, wherein the rotating element comprises a fan.

12. The method of claim 10, wherein the rotating element comprises a turbine.

13. The method of claim 10, wherein the rotating member also comprises a plurality of adjustable blades, and the method also includes control of the angle of a plurality of adjustable blades relative to a plane perpendicular to the axis of rotation of the rotating element.

14. The method according to paragraph 10, also including the simultaneous transfer of electrical energy from both the electric generator and from an external power source to the electrolyzer.

15. The method according to paragraph 10, also including: transmitting electrical energy from an electric generator to a battery pack containing one or more batteries; and charging one or more batteries.

16. The method according to paragraph 15, also including: selective transfer of electrical energy from an electric generator to a battery bank or electrolyzer; and selectively transferring electrical energy from at least one external power source to a battery pack charger or electrolyzer.

17. The method according to claim 10, in which at least one additional rotating element is located downstream of the rotating element and is mechanically connected to an additional electric generator, and an additional electric generator is electrically connected in series with said electric generator.

18. The method according to claim 17, also including controlling at least one additional rotating element.

Images