Cooling apparatus and cooling system for electrical conductors within an electrochemical plant

Abstract

The present disclosure advantageously provides an improved cooling apparatus or cooling system for cooling an electrical conductor within an electrochemical plant. The configurations disclosed herein provide advantages and improvements in a cooling system for the electrochemical plant. In one example, a cooling apparatus includes an electrical conductor configured to provide power to at least one electrochemical stack of the electrochemical system. The cooling apparatus further includes a component having a hollow channel in fluid communication with the electrical conductor, wherein the component is configured to receive a liquid coolant and cool the electrical conductor during operation of the electrochemical system.

Description

COOLING APPARATUS AND COOLING SYSTEM FOR ELECTRICAL CONDUCTORS WITHIN AN ELECTROCHEMICAL PLANT

[0001] The present patent document claims the benefit of United States Provisional Patent Application No. 63 / 646,261, filed May 13, 2024, which is hereby incorporated by reference in its entirety.FIELD

[0002] The following disclosure relates to cooling apparatuses and cooling systems, in particular for cooling electrical conductors providing power to at least one electrochemical stack of the electrochemical plant.BACKGROUND

[0003] Electrochemical 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. Hydrogen has been considered as an ideal energy carrier to store renewable energy. Proton exchange membrane water electrolysis (PEMWE) as a means for hydrogen production offers high product purity, fast load response times, small footprints, high efficiencies, and low maintenance efforts. It is regarded as a promising technology, especially when coupled with renewable energy sources.

[0004] In recent years, improvements in operational efficiency have made electrochemical systems competitive market solutions for energy storage, generation, and / or transport. For example, the cost of generation may be below $6 per kilogram of hydrogen in some cases. Increases in efficiency and / or improvements in operation will continue to drive installation of electrochemical systems.SUMMARY

[0005] In one embodiment, a cooling apparatus for an electrochemical system is provided. The cooling apparatus includes an electrical conductor configured to provide power to at least one electrochemical stack of the electrochemical system. The cooling apparatus further includes a component having a hollow channel in fluid communication with the electrical conductor, wherein the component is configured to receive a liquid coolant and cool the electrical conductor during operation of the electrochemical system.

[0006] In another embodiment, an electrochemical system is provided. The electrochemical system includes at least one electrochemical stack, wherein each electrochemical stack of the at least one electrochemical stack comprises a plurality of electrochemical cells. The electrochemical system further includes at least one power supply configured to provide power to the at least one electrochemical stack. The electrochemical system further includes a first electrical conductor connecting the at least one power supply to a first electrochemical stack of the at least one electrochemical stack at a first terminal. The electrochemical system further includes a second electrical conductor connecting the at least one power supply to the first electrochemical stack or an additional electrochemical stack positioned in series with the first electrochemical stack at a second terminal. The electrochemical system further includes at least one first component, each first component having a hollow channel in fluid communication with the first electrical conductor, wherein the at least one first component is configured to receive a liquid coolant and cool the first electrical conductor during operation of the electrochemical system. The electrochemical system further includes at least one second component, each second component having a hollow channel in fluid communication with the second electrical conductor, wherein the at least one second component is configured to receive the liquid coolant from the first electrochemical stack orthe additional electrochemical stack and cool the second electrical conductor during the operation of the electrochemical system.

[0007] 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

[0008] Exemplary embodiments are described herein with reference to the following drawings.

[0009] Figure 1A depicts an example of an electrochemical cell.

[0010] Figu re IB depicts an example of a system including an electrochemical stack having a plurality of electrochemical cells of Figure 1A.

[0011] Figure 2 depicts an example of an electrochemical plant.

[0012] Figure 3 depicts an additional example of an electrochemical plant.

[0013] Figure 4 depicts an example of a cooling system of an electrochemical plant.

[0014] Figure 5 depicts an example of a cooling apparatus for cooling an electrical conductor, the cooling apparatus having a component having a hollow channel connected to a terminal or manifold for receiving a cooling fluid to cool an electrical conductor.

[0015] Figure 6 depicts an additional example of a cooling apparatus for cooling an electrical conductor, the cooling apparatus having a hollow channel component connected to a terminal on an outer surface of the component at one end of the component.

[0016] Figures 7-10 depict examples of manifolds of cooling apparatuses for cooling electrical conductors, the manifolds having at least one inlet port for receiving a cooling fluid supply tube or a conductor tube and at least one outlet port configured to receive the opposite of the inlet port.

[0017] Figure 11 depicts an example of electrical connections between a power source and a plurality of electrochemical stacks positioned in series.

[0018] Figures 12-17 depict examples of cooling systems for a plurality of electrochemical stacks positioned in series.DETAILED DESCRIPTION

[0019] The present disclosure advantageously provides devices, systems, and methods for cooling electrical conductors within an electrochemical plant. Specifically, the disclosure describes devices, systems, and methods that may advantageously provide cooling fluid to regulate or control the temperature of the electrical conductors providing power from one or more power supply modules to one or more electrochemical stacks within an electrochemical system. At high current, the usage of cooling fluid to cool the electrical conductors may advantageously allow for a reduction of conductor materials thereby allowing lowered material costs and structural requirements. Reduced required material may advantageously allow for higher density packaging of the power conduction leading to overall smaller, lighter, less expensive and more power dense electrochemical plants.

[0020] In the current state of the art, busbars may be used within the electrochemical plant to assist in delivering the substantial amount of current necessary to operate the electrochemical stack(s). To supply the required current to the electrochemical stack(s),particularly for high current operations, the electrolyzer bussing requires runs of thick busbar with additional structural support members and bolted joints.

[0021] As described herein, coolant-cooled cables and / or tubes may be used in place of the busbar systems. Such coolant-cooled cables / tables may advantageously support a same amount of current as a traditionally-sized busbar but using a fraction of the metal conductor (e.g., copper). This reduction in material may also advantageously reduce the amount of structural support and the construction of the cables / bus tubes may run for a much longer distance without the need for structural joints. Additionally, busbars may be provided in smaller sections than metal (e.g., copper) tubes, therein advantageously reducing a need for joints for bus tubes, and thereby reducing install cost and joint resistances. These joint and weight savings allow for reduced installation, maintenance, structural, and metal (e.g., copper) costs.

[0022] Additionally, in certain examples, the coolant-cooled cables may advantageously use the existing cooling system and piping within the electrochemical plant to provide the coolant to the conductor cables / tubes providing current to the electrochemical stack.

[0023] Further, the proposed solutions described herein may advantageously provide a tighter spacing of conductor lines by allowing tighter bends, and more current to be bussed per unit volume. Such a cooled conductor solution may additionally advantageously allow for more connection tolerance, therein eliminating the addition of flexible jumpers to the ends of large bus bars.

[0024] For example, an extremely power dense electrochemical stack may need to be fed by a very heavy (~300 kg / m) set of stiff bus bars necessitating significant supporting structures, and the requisite installation costs. The cross section of the bus bar may be 0.186 m2. For a 5 m bus bar, the bus bar may have at least 1 intermediate connection and may need a flexible joint to land on the stack due to mechanical tolerances. Through the advantageous implementation of a coolant-cooled conductor (e.g., coolant-cooled copper piping) for a same length may reduce the weight of the electrical conductor to 20 kg / m and reduce the cross section to 0.015 m2, thereby requiring much less support. The copper tubing may additionally have enough flexibility that the tubing may be installed without the need for an additional flex joint. This solution may also advantageously reduce the numberof bolts securing the conductor by 1.5 to 2 orders of magnitude, advantageously reducing installation costs, joint resistance, and potential for bad electrical joints.

[0025] This reduction in metal (e.g., copper) may also advantageously insulate the plant from future met pricing. As electrification increases across many industries, the cost of copper will go up as well.Electrochemical Cells / Stacks

[0026] 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++>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."

[0027] 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 16Amps / cm2, at least 17 Amps / cm2, at least 18 Amps / cm2, at least 19 Amps / cm2, at least 20Amps / 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). In additional examples, the amount of water (e.g., deionized (DI) water) transferred to or circulated through each cell of the stack may be in a range of 0.25-1mL / 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.

[0028] 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 another embodiment, 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.

[0029] 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.

[0030] During electrolysis, oxygen (O2) is produced at the anode side of the electrolytic cells and hydrogen ( H 2) 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.

[0031] 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.

[0032] 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

[0033] The electrochemical cells and stacks discussed within Figures 1A and IB may be incorporated into an electrochemical plant having one or more electrochemical stacks (e.g., a plurality of electrochemical stacks).

[0034] The one or more 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 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.

[0035] In other embodiments, the one or more electrochemical stacks may be used in the formation of a large-scale electrochemical plant that may be configured to consume at least 10 megawatts (MW) of power, at least 25 MW, at least 50 MW, at least 75 MW, at least 100 MW, 10-100 MW, 25-100 MW, or 50-100 MW.

[0036] The one or more electrochemical stacks may be incorporated within an electrochemical plant configured for this large scale power generation.

[0037] Figure 2 depicts one example 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. The cooling section includes an embodiment of a cooling system of the present disclosure that is discussed further below. Each section may advantageously include one or more modules. Centralized piping and electrical cables may be provided within this configuration to connect various modules to each other.

[0038] Figure 3 depicts another example 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 including an embodiment of a cooling system of the present disclosure, which is discussed further below. Each section may advantageously include one or more modules.

[0039] In this particular example, the electrochemical plant includes four power supply modules positioned in a linear arrangement. Each power supply module 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 a cooling unit within the plant). Additional or fewer power supply units may be developed / built with each power supply module.

[0040] The power supply units within the power supply modules 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.

[0041] The power supply modules may further include one or more medium voltage transformers rated in a range of 1-70 kV 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.

[0042] 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.

[0043] In certain examples, the power supply section of the electrochemical plant may further include a power distribution center or building. The power distribution center 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 may include one or more motor control centers, process logic controllers, and operator stations, 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.

[0044] As depicted in Figure 3, the electrochemical plant may include a plurality of electrolysis modules (e.g., modules A, B, C, and D) positioned in a linear arrangement in the center of the plant for ease of deployment or for capacity additions. Fewer or more modulesmay be present within the plant. Further, as shown in Figure 3, the electrolysis modules may be positioned adjacent to the power supply modules. In this particular example, one electrolysis module is configured to be connected to and receive power from two power supply modules. Alternative arrangements are also possible wherein three or more power supply modules provide power to a single electrolysis module, or a single power supply module provides power to one or two electrolysis modules.

[0045] In this particular example, each electrolysis module includes four separate electrochemical stacks. Fewer or more stacks may be present for a particular module.

[0046] In this particular example, centralized piping and electrical cables may be present within each module and between the various electrolysis modules. For example, electrolysis module A 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, as depicted in Figure 3, four stacks within a single electrolysis module may be connected and fed with a 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.

[0047] Further, shared and centrally located electrical cables may be provided from a power supply module adjacent to the respective stack module.

[0048] In certain examples, a minimized amount of piping may be configured to attach one electrolysis module with an additional, adjacent electrolysis module.

[0049] Returning to Figure 3, the electrochemical plant may further include 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.

[0050] For example, the process equipment section may include various modules 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. In certain examples, the hydrogen product processing module may be developed toinclude a condenser, a water knockout drum and coalescing filter, allowing for high hydrogen purity to be achieved without a need for a dedicated dryer module.

[0051] The process equipment section may also include 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 the electrochemical 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.

[0052] Additional modules within the process equipment section of the plant may be 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.

[0053] Returning back to Figure 3, the electrochemical plant further includes a cooling section or segment of the plant that may be positioned in a linear arrangement adjacent to the process equipment section.

[0054] Figure 4 depicts an embodiment of a cooling system 200 for an electrochemical plant according to the present disclosure. The cooling system 200 may include one or more cooling modules, a manifold, and at least one cooling loop (e.g., in some cases, a single cooling loop). Each cooling module may include a plurality of coolers (e.g., dry or wet coolers) configured to transfer coolant and / or water and reject waste heat generated in a plurality of separate modules of the electrochemical plant. The plurality of separate modules may be any of the above-mentioned modules. In these depicted examples, the plurality of separate modules includes an electrolysis module and a power supply module.

[0055] The cooling system 200 may also include a manifold configured to connect the plurality of coolers in the cooling modules in parallel. The manifold includes at least one fluid inlet and at least one fluid outlet through which coolant may flow through to the one or more cooling loops. In certain examples, the cooling system 200 includes a single coolant loop configured to feed a coolant to all the systems / modules within the electrochemical plant (e.g., anode, cathode, rectifier, etc.). In other examples, the cooling system 200 includes multiple coolant loops configured to feed each system / module individually or configured to feed a subset of systems / modules within the plant.

[0056] The cooling loop may include cooling lines configured to provide fluid communication between the cooling modules and each module of the plurality of separate modules within the electrochemical plant. The plurality of coolers within the cooling modules may be connected (e.g., in parallel) to the singular manifold.

[0057] In this example, the cooling lines of the cooling loop are configured to connect to the cooling fluid inlet and the cooling fluid outlet of the manifold with each module of the plurality of separate modules within the electrochemical plant.

[0058] In certain examples, the cooling loop may also include one or more pressure regulators (not illustrated) and flow control valves (not illustrated), configured to control the coolant flowing through the cooling loop such as to balance the flow and / or prevent over pressurization in the cooling loop. The cooling loop may also include one or more sensors (not illustrated) to measure the pressure and / or temperature of the coolant flowing through the cooling lines.

[0059] In certain examples, the cooling system 200 may also include at least one pump configured to adjust (e.g., raise) a pressure of the coolant flowing through the cooling loop. In this depicted example, the cooling system 200 includes power electronics cooling booster pumps configured to raise a pressure of the coolant flowing through the cooling loop to the power supply module. The cooling system 200 also includes main cooling pumps configured to raise a pressure of the coolant flowing into the cooling module. However, any number of pumps may be used, and the present disclosure is not limited to the power electronics cooling booster pumps and the main cooling pumps.

[0060] In certain examples, the cooling system 200 may further include a controller 270 and a data acquisition unit 272. The controller 270 is in communication with the pressure sensors, the flow control valves, the pressure regulators, the pumps, temperature sensors within the electrochemical system, and any additional sensors within the system. The data acquisition unit 272 may be operable to measure, monitor, and / or receive system data in real-time.

[0061] For example, the controller 270 may be configured to control a pressure of the coolant flowing through the cooling lines via an adjustment to at least one pressure regulator of the cooling loop. The controller 270 may further be configured to control a flow rate of the coolant flowing through the cooling lines via an adjustment to at least one flow control valve of the cooling loop. The controller 270 may also be configured to control the pumps to pressurize the coolant in the cooling loop.

[0062] In certain examples, one or more control valves within the cooling loop may be configured to control a flow rate of the coolant entering and / or leaving the plurality of coolers of the cooling modules. The flow rate of the coolant entering and / or leaving the coolers may be any configurable flow rate taking into consideration the operating parameters of the electrochemical system. In certain examples, the flow rate may be at least 0.1 liters / minute (L / min), at least 1 L / min, at least 10 L / min, at least 100 L / min, at least 200 L / min, at least 1000 L / min, at least 2000 L / min, in a range of 0.1-2000 liters per minute (L / min), 10-2000 L / min, 100-2000 L / min, 0.1-200 L / min, 1-200 L / min, 10-200 L / min, 0.1- 1000 L / min, 1-1000 L / min, or 10-1000 L / min.

[0063] The controller 270 is further configured to regulate the flow rate of the coolant within the cooling loop for the purpose of cooling the various distinct modules within the electrochemical plant. For instance, the controller 270 can receive data from sensors placed along the cooling loop. Using this data, the controller 270 determines the optimal temperature and pressure needed for effectively cooling both the plurality of separate modules, e.g., using a minimum amount of energy consumption in the cooling process. In other words, the cooling system is configured to operate at the determined optimal temperature needed for cooling both the electrolysis module and the power supply module.

[0064] In certain examples, the controller 270 may be configured to receive one or more temperature measurements within the cooling loop, e.g., adjacent to an electrical conductor providing power to an electrochemical stack. Based on the measured temperature, the controller may adjust a flow rate of coolant to maintain a temperature of the electrical conductor at or below a predefined setting or threshold temperature.

[0065] Additionally, the controller 270 may fine-tune the pressure and temperature of the coolant itself, using the pressure regulators and control valves, based on the identified optimal temperature and pressure before supplying the coolant to each individual module connected to the cooling loop. Moreover, the controller 270 has the capability to adjust the coolant's characteristics, utilizing pressure regulators and control valves, to ensure a consistent coolant temperature and pressure provided to each module.

[0066] This dynamic controller helps maximize the efficiency of the electrochemical plant by tailoring the coolant conditions based on real-time data and specific operational requirements of each module.

[0067] Referring back to Figure 4, the cooling modules are configured to transfer the coolant via the coolant loop to each module of the plurality of separate modules of the electrochemical system. Additionally, the cooling modules are configured to receive, via the cooling loop, the coolant from each module of the plurality of separate modules and reject the waste heat collected by the coolant received from each module of the plurality of separate modules to a surrounding environment.

[0068] In this depicted example, the cooling loop is configured to be in fluid communication with the electrolysis module. The electrolysis module may include one or more electrochemical stacks (e.g., a plurality of electrochemical stacks). The plurality of electrochemical stacks are connected via a same cathode heat exchanger and a same anode heat exchanger that are configured to be in fluid communication with the cooling modules and the power supply module via the cooling lines. Additionally, the plurality of electrochemical stacks are connected via a same anode inlet water supply and a same anode outlet water supply.

[0069] In certain examples the electrolysis module may include one or more electrochemical stacks (e.g., a plurality of electrochemical stacks). The plurality ofelectrochemical stacks are connected via a same cathode heat exchanger and a same anode heat exchanger that are configured to be in fluid communication with the cooling modules and the power supply module via the cooling lines.

[0070] Additionally, in this depicted example, the cooling loop is configured to be in fluid communication with the power supply module. The power supply module may include one or more medium voltage transformers rated in a range of 1 - 70 kV, one or more AC-to- DC power converters, and one or more rectifiers configured to provide power to the electrolysis module of the electrochemical plant.Cooling of Electrical Conductor Lines

[0071] As noted above, the cooling system within the electrochemical plant may be in communication with the electrochemical stack(s) as well as the power supply module(s) within the overall system.

[0072] Specifically, in certain examples, the cooling system may advantageously provide cooling fluid to regulate or control the temperature of the electrical conductors providing power from the power supply module(s) to the electrochemical stack(s). In certain examples, the cooling system may include a single coolant loop configured to feed a coolant to all the systems / modules within the electrochemical plant (e.g., anode, cathode, rectifier, etc.). In other examples, the cooling system may include multiple coolant loops configured to feed each system / module individually or configured to feed a subset of systems / modules within the plant. In yet other examples, an external cooling source outside of the cooling system or cooling loops within the cooling system to provide a cooling fluid to regulate or control the temperature of the electrical conductors providing power from the power supply module(s) to the electrochemical stack(s).

[0073] Figures 5-10 depict examples of advantageous cooling apparatuses for electrochemical systems. For example, Figure 5 depicts a non-limiting example of a cooling apparatus 500 having a component 502 having a hollow channel connected to a terminal or manifold 504.

[0074] In this example, the terminal or manifold 504 includes a first opening or inlet port 506 configured to receive a cooling fluid (e.g., via a liquid cooling piping connector suchas a barbed fitting) for transferring the liquid coolant into or from the hollow channel of the component. The terminal or manifold 504 further includes a second opening or outlet port 508 configured to receive the hollow channel component. The manifold further includes a stack collector plate interface 510 having two holes for bolting or otherwise securing the manifold to a surface of the electrochemical stack or other apparatus within the electrochemical plant. As noted above, the number of bolts needed to secure the conductor / manifold to the stack may advantageously be fewer than the current state of the art due a reduced overall weight associated with the cooled conductor apparatus described herein. In other words, the manifold depicted in Figures 5-10 may have a smaller overall profile with a smaller number of openings and lower number of bolts required, advantageously reducing installation costs, joint resistance, and potential for bad electrical joints.

[0075] In the depicted example within Figure 5, the inlet port 506 has a barbed fitting configured to receive the liquid coolant piping connector (e.g., cooling fluid tube / hose / pipe). Further, each hollow channel component is configured to receive the cooling fluid via the manifold. The cooling fluid or liquid coolant may include process water from a cooling system within the electrochemical system. Alternatively, the liquid coolant may be provided from a cooling source external to the electrochemical system. In yet another example, the liquid coolant may include water, propylene glycol, mineral oil, or combinations thereof. In some examples, the water may include process water from a cooling system within the electrochemical system, reverse osmosis deionized (ROID) water, demineralized water, sea water, or combinations thereof.

[0076] In certain examples, the hollow channel of the component 502 may be a hollow tube, hollow pipe, hollow flexible cable, or include a plurality of extrusion tubes having hollow passages configured to receive the liquid coolant or cooling fluid. While Figure 5 and additional depicted examples herein show cooled tubes / pipes, cooled flexible cables may be implemented in a similar fashion. While these flexible cables may be more expensive than cooled tubing, they may advantageously provide greater flexibility and may be installed in certain areas of the electrochemical plant where such operational flexibility is desirable.

[0077] In certain examples, the composition of the component having the hollow channel may function as the electrical conductor. Alternatively, to the extent the component includes a plurality of extrusion tubes, one or more (e.g., all) of the extrusion tubes may have a composition configured to function as the electrical conductor. For example, the composition of the component or extrusion tubes within the component may include copper metal that is configured to transfer current to the electrochemical stack.

[0078] In certain examples, the hollow channel component may be formed via a custom extrusion process configured to optimize or achieve a specific cross section of the electrical conductor (e.g., copper metal). This may be advantageously employed where a highly ampere dense section is needed, such as passing large currents through current transducers which often have small openings that are rectangular.

[0079] Alternatively, the component may be configured to receive at least a portion of the electrical conductor (e.g., an electrical cable) within the hollow channel that is configured to provide power to at least one electrochemical stack of the electrochemical system. For instance, a portion of the electrical cable may be positioned within an inner tube surrounded by the component having the hollow channel such that the liquid coolant is configured to flow between an outer surface of the inner tube and an inner surface of the component having the hollow channel.

[0080] Alternatively, the electrical conductor (e.g., electrical cable) may be positioned on an outside surface of the component, i.e., abutting the component having the hollow channel for receiving a cooling fluid. In certain examples, the electrical conductor is an electrical cable such as a co-axial flexible wire.

[0081] In each of these scenarios, the cooling fluid, via transfer through the hollow channel(s) of the component, is advantageously configured to cool an electrical conductor during operation of the electrochemical system, therein controlling or regulating a temperature of the electrical conductor providing power to an electrochemical stack.

[0082] As noted above, at high current, the usage of cooling fluid to cool the electrical conductor may advantageously allow for a reduction of conductor materials thereby allowing lowered material costs and structural requirements. Reduced required materialmay advantageously allow for higher density packaging of the power conduction leading to overall smaller, lighter, less expensive and more power dense electrochemical plants.

[0083] Further, the hollow channel components (e.g., coolant-cooled cables and / or tubes) may replace busbar systems in current electrochemical plant configurations, which may advantageously support a same amount of current as a traditionally-sized busbar but using a fraction of the metal conductor (e.g., copper). This reduction in material may also advantageously reduce the amount of structural support and the construction of the cables / bus tubes may run for a much longer distance without the need for structural joints. Additionally, busbars may be provided in smaller sections than metal (e.g., copper) tubes, therein advantageously reducing a need for joints for bus tubes, and thereby reducing install cost and joint resistances. These joint and weight savings allow for reduced installation, maintenance, structural, and metal (e.g., copper) costs.

[0084] Additionally, in certain examples, the coolant-cooled cables may advantageously use the existing cooling system and piping within the electrochemical plant to provide the coolant to the conductor cables / tubes providing current to the electrochemical stack.

[0085] Further, the proposed solutions described herein may advantageously provide a tighter spacing of conductor lines by allowing tighter bends, and more current to be bussed per unit volume. Such a cooled conductor solution may additionally advantageously allow for more connection tolerance, therein eliminating the addition of flexible jumpers to the ends of large bus bars.

[0086] For example, an extremely power dense electrochemical stack may need to be fed by a very heavy (~300 kg / m) set of stiff bus bars necessitating significant supporting structures, and the requisite installation costs. The cross section of the bus bar may be 0.186 m2. For a 5 m bus bar, the bus bar may have at least 1 intermediate connection and may need a flexible joint to land on the stack due to mechanical tolerances. Through the advantageous implementation of a coolant-cooled conductor (e.g., coolant-cooled copper piping) for a same length may reduce the weight of the electrical conductor to 20 kg / m and reduce the cross section to 0.015 m2, thereby requiring much less support. The copper tubing may additionally have enough flexibility that the tubing may be installed without the need for an additional flex joint. This solution may also advantageously reduce the numberof bolts securing the conductor by 1.5 to 2 orders of magnitude, advantageously reducing installation costs, joint resistance, and potential for bad electrical joints.

[0087] This reduction in metal (e.g., copper) may also advantageously insulate the plant from future met pricing. As electrification increases across many industries, the cost of copper will go up as well.

[0088] Figure 6 depicts a further example of a cooling apparatus 600 having a hollow channel component 302 (e.g., cooling tube) connected to a terminal 604 on an outer surface of the component at one end of the component. In this example, an intermediate manifold in Figure 5 is not present. Further, each cooling tube within the example includes a hollow channel configured to receive the cooling fluid via a liquid coolant piping connector (e.g., barbed fitting).

[0089] In certain examples, such as described above with reference to Figure 5, the composition of the component having the hollow channel may function as the electrical conductor. Alternatively, to the extent the component includes a plurality of extrusion tubes, one or more (e.g., all) of the extrusion tubes may have a composition configured to function as the electrical conductor. For example, the composition of the component or extrusion tubes within the component may include copper metal that is configured to transfer current to the electrochemical stack.

[0090] In some alternative examples, the component is configured to receive at least a portion of the electrical conductor (e.g., an electrical cable) within the hollow channel that is configured to provide power to at least one electrochemical stack of the electrochemical system. For instance, a portion of the electrical cable may be positioned within an inner tube surrounded by the component having the hollow channel such that the liquid coolant is configured to flow between an outer surface of the inner tube and an inner surface of the component having the hollow channel.

[0091] Alternatively, the electrical conductor (e.g., electrical cable) may be positioned on an outside surface of the component, i.e., abutting the component having the hollow channel for receiving a cooling fluid. In certain examples, the electrical conductor is an electrical cable such as a co-axial flexible wire.

[0092] In all of these scenarios, the cooling fluid, via transfer through the hollow channel(s) of the component, is advantageously configured to cool an electrical conductor during operation of the electrochemical system, therein controlling or regulating a temperature of the electrical conductor providing power to an electrochemical stack.

[0093] Figures 7 and 8 depict examples of a manifold 700, such as the example within Figure 5. In these figures, the manifold 700 includes a single inlet port 706 and a single outlet port 708. The inlet port 706 may be configured to receive a cooling fluid supply tube or a conductor tube, while the outlet port 708 may be configured to receive the opposite of the inlet port. As depicted in these figures, the manifold further includes a stack collector plate interface 710 having two holes 712, 714 for bolting or otherwise securing the manifold to a surface of the electrochemical stack or other apparatus within the electrochemical plant.

[0094] Figures 9 and 10 depict further examples of a manifold 900. In these non-limiting examples, the manifold 900 includes two inlet ports 902, 904 and one outlet port 906 (or, alternatively, one inlet port 906 and two outlet ports 902, 904). The manifold further includes a stack collector plate interface 910 having four holes 912, 914, 916, 918 for bolting or otherwise securing the manifold to a surface of the electrochemical stack or other apparatus within the electrochemical plant. Further, it should be noted that while these examples in Figures 7-10 depict certain manifold configurations, other configurations may also exist (e.g., one inlet / three outlet ports, etc.)

[0095] Figure 11 depicts an example of electrical connections between a power source and a plurality of electrochemical stacks positioned in series. In this figure, the electrochemical plant includes two power supply modules (e.g., two rectifiers) configured to provide power to two electrochemical stacks within the electrochemical plant / system. In this example, the two stacks are positioned in series. The system is not limited to such an arrangement (i.e., a different number of rectifiers and stacks are possible).

[0096] As depicted in Figure 11, electrical conductors connect the output of each rectifier and the input or first terminal of the first stack. In this example, these conductors are direct current (DC) positive conductors, and the first terminal of the first stack represents a positive terminal. Additionally, electrical conductors connect the output ofeach rectifier and the last (second) stack or second terminal of the series of stacks. In this example, these conductors are DC negative conductors, and the second terminal represents a negative terminal. Further, a midpoint conductor (DC midpoint) connects each stack within the series of stacks together (i.e., stack 1 and stack 2 are connected via a DC midpoint conductor).

[0097] In this example, each of these electrical conductors (i.e., the DC positive, DC negative, and DC midpoints) may be configured to be a cooled by a cooling fluid, therein providing a liquid cooled conductor. Specifically, a cooling fluid may be provided to each electrical conductor within the system to advantageously regulate or control the temperature of the conductor. Non-limiting examples of such cooling apparatuses may include those examples identified within Figures 5-10, discussed above.

[0098] The concept of flowing liquid through the conductor may advantageously increase the current density by a factor of 20 for the stack-to-stack liquid cooled connection (identified by the DC midpoint connection) and increase the current density by a factor of 4 for the rectifier to stack liquid cooled connection. Because the current density goes up, the required amount of electrical conductor (e.g., copper metal) to carry current also goes down by the same factor, which advantageously reduces the overall weight of copper required and thereby reduces the amount of structural strength and support need to hold the weight of the copper. Another advantage for such electrically cooled conductors as described herein is the amount of flexibility this arrangement offers over a rigid busbar setup in terms of tolerance stack up. Furthermore, such electrically cooled conductors may advantageously be scalable and offer greater cost savings for larger electrochemical plant operations.

[0099] As noted above, at a high current operation within the electrochemical system (e.g., at a current density of 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 least14 Amps / cm2, at least 15 Amps / cm2, at least 16 Amps / cm2, at least 17 Amps / cm2, at least18 Amps / cm2, at least 19 Amps / cm2, at least 20 Amps / cm2, at least 25 Amps / cm2, at least30 Amps / cm2, in a range of 1-30 Amps / cm2, in a range of 3-20 Amps / cm2, in a range of 3-15Amps / cm2, in a range of 3-10 Amps / cm2, or in a range of 10-20 Amps / cm2), the use ofcooling fluid to cool the electrical conductors may advantageously allow for a reduction of conductor materials thereby allowing lowered material costs and structural requirements. Reduced required material may advantageously allow for higher density packaging of the power conduction leading to overall smaller, lighter, less expensive and more power dense electrochemical plants.

[0100] Figures 12-17 depict further examples of cooling flow arrangements within the liquid cooled conductors within the electrochemical plant.

[0101] For example, Figure 12 depicts two electrochemical stacks of an electrochemical plant having liquid cooled conductors. Fewer or more electrochemical stacks are also possible. In such examples, each electrochemical stack includes a plurality of electrochemical cells.

[0102] The example in Figure 12 follows from the arrangement described and depicted in Figure 11. Specifically, at least one power supply (i.e., one or more power modules) is configured to provide power to a first stack. In the example, at least one electrical conductor connect the at least one power supply to a first electrochemical stack at a first terminal or manifold. This connection is via two electrical conductors leading to a first manifold. Each of the electrical conductors is cooled via a component having a hollow channel in fluid communication with the respective electrical conductor. Each component is configured to receive a liquid coolant and cool the electrical conductor during operation of the electrochemical system. While this example depicts two electrical conductors providing power to the first stack, the number of conductor lines is variable, and may be less (i.e., only one) or more (e.g., more than two). The number of electrical conductors may depend on the power requirements for operating the electrochemical stack.

[0103] As noted above with respect to the discussion for Figure 5, the hollow channel of the component may be a hollow tube, hollow pipe, hollow flexible cable, or include a plurality of extrusion tubes having hollow passages configured to receive the liquid coolant or cooling fluid. In certain examples, the composition of the component having the hollow channel may function as the electrical conductor. Alternatively, to the extent the component includes a plurality of extrusion tubes, one or more (e.g., all) of the extrusion tubes may have a composition configured to function as the electrical conductor. Forexample, the composition of the component or extrusion tubes within the component may include copper metal that is configured to transfer current to the electrochemical stack.

[0104] In certain examples, the hollow channel component may be formed via a custom extrusion process configured to optimize or achieve a specific cross section of the electrical conductor (e.g., copper metal). This may be advantageously employed where a highly ampere dense section is needed, such as passing large currents through current transducers which often have small openings that are rectangular.

[0105] Alternatively, the component may be configured to receive at least a portion of the electrical conductor (e.g., an electrical cable) within the hollow channel that is configured to provide power to at least one electrochemical stack of the electrochemical system. For instance, a portion of the electrical cable may be positioned within an inner tube surrounded by the component having the hollow channel such that the liquid coolant is configured to flow between an outer surface of the inner tube and an inner surface of the component having the hollow channel.

[0106] Alternatively, the electrical conductor (e.g., electrical cable) may be positioned on an outside surface of the component, i.e., abutting the component having the hollow channel for receiving a cooling fluid. In certain examples, the electrical conductor is an electrical cable such as a co-axial flexible wire.

[0107] In each of these scenarios, the cooling fluid, via transfer through the hollow channel(s) of the component, is advantageously configured to cool an electrical conductor during operation of the electrochemical system, therein controlling or regulating a temperature of the electrical conductor providing power to an electrochemical stack.

[0108] As shown in Figure 12, at the first manifold, the cooling fluid streams from each cooling tube are combined and transferred through the manifold to a combined outlet tube. The outlet tube is configured to transport the cooling fluid to the bottom of the stack to connect with a second manifold.

[0109] At the second manifold, the combined cooling fluid stream is transferred through the second manifold to one or more cooling tubes (e.g., two cooling tubes in this example). Each of these tubes is configured to cool a respective electrical conductor providing power between the first stack and second stack in the series of stacks. Again, while this exampledepicts two electrical conductors providing power between the two stacks, the number of conductor lines is variable, and may be less (i.e., only one) or more (e.g., more than two).

[0110] Additionally, each of the cooling tubes connecting the two stacks is configured to transport the cooling fluid from the second manifold, therein continuing to provide an advantageous cooling source for the electrical conductors positioned within the tubes.

[0111] As depicted in Figure 12, the cooling tubing from the second manifold is connected to a third manifold positioned at the second electrochemical stack. At the third manifold, the cooling fluid streams from each cooling tube are combined and transferred through the third manifold to a combined outlet tubing. The outlet tubing is configured to transport the cooling fluid to the top of the second stack to connect with a fourth manifold at the outlet of the second stack.

[0112] At the fourth manifold, the combined cooling fluid stream is transferred through the fourth manifold to one or more cooling tubes (e.g., two cooling tubes in this example). Each of these tubes is configured to cool a respective electrical conductor providing power between the second stack and a subsequent stack (if additional stacks are present) or one or more power modules of the electrochemical system (if the second stack represents a final stack of the series of stacks). Again, while this example depicts two electrical conductors, the number of conductor lines is variable, and may be less (i.e., only one) or more (e.g., more than two).

[0113] In this example of Figure 12, the second stack represents a final stack in the series of electrochemical stacks. As such, the two cooling tubes are configured to transfer the cooling fluid streams back to a cooling source / system within the electrochemical system. This is advantageous in being able to reuse / recycle the cooling fluid for subsequent cycles through the electrochemical stacks / system. This recycling process may include transferring the exiting cooling fluid streams from the last electrochemical stack to one or more heat exchangers to effectively reduce the temperature of the exiting cooling fluid from the stacks for subsequent use at the inlet of the stacks.

[0114] Figures 13A-13B depict an additional example of cooling tubing running to a positive terminal of a first stack of a series of electrochemical stacks (Figure 13A) as well as cooling tubing running to a negative terminal of a last (second) stack of the series ofelectrochemical stacks (Figure 13B). In this example, eight cooling tubes are provided for the positive terminal of the first stack in groups of two. Each cooling tube is configured to cool an electrical conductor providing power to the first stack. These eight electrical conductors associated with the eight cooling tubes terminate at a current source (e.g., one or more power modules).

[0115] S imilarly, eight cooling tubes are provided for the negative terminal of the second stack in groups of two. Each cooling tube is configured to cool an electrical conductor providing power to the second stack. These eight electrical conductors associated with the eight cooling tubes terminate at an additional current source (e.g., one or more power modules).

[0116] Figures 14A-B depict an additional example of cooling tubing running between adjacent stacks of a series of electrochemical stacks. In this example, Figure 14A depicts eight cooling tubes are provided for the transfer of power between the two electrochemical. Each cooling tube is configured to cool an electrical conductor transferring power between the two stacks.

[0117] Figure 14B additionally depicts an example of a manifold configured to receive coolant through one or more ports and transfer the coolant out of another one or more ports. In this particular example, the manifold depicts two inlet ports configured to receive the cooling fluid and one exit or outlet port configured to transfer the cooling fluid out from the manifold to a downstream location (e.g., an inlet of another manifold or a heat exchanger of the electrochemical system / plant). Alternatively, the example may depict one inlet port configured to receive the cooling fluid and two outlet ports configured to transfer the cooling fluid out from the manifold to a downstream location.

[0118] The example of the manifold in Figure 14B additionally depicts a non-limiting example of stack collector plate interface configured to be secured to an electrochemical stack (e.g., via bolts being inserted into each of the six holes and attached to the respective stack).

[0119] Figures 15-17 depict additional examples of a cooling path of the cooling fluid through two electrochemical stacks arranged in series. Similar to the examples depicted in Figures 13A-B and 14A-B, the non-limiting example in Figure 15 includes a cooling fluidsupply line configured to provide a cooling fluid to a manifold having one inlet port configured to receive the cooling fluid supply line and four outlet ports configured to transfer the cooling fluid through four tubes to a current source. At the current source, the four cooling tubes are connected to four manifolds, each of these manifolds having one inlet port and two outlet ports. These eight outlet ports are connected to cooling tubes associated with an electrical conductor configured to provide power to a first electrochemical stack. The cooling fluid transferred through these eight outlet ports to the first stack is configured to advantageously regulate or control the temperature of the electrical conductors.

[0120] As shown in Figure 15, the cooling fluid at the first stack is transferred from the eight cooling tubes to a plurality of manifolds, each manifold having two inlet ports and one outlet port. Subsequently, the cooling fluid transferred from the first stack through a plurality of isolation tubes (i.e., not including any electrical conductors) to a next plurality of manifolds at the second stack. This arrangement may be advantageous in allowing the same cooling fluid to flow though busbars at different potential.

[0121] From the location at the manifolds at the second stack, the isolated coolant is provided to a plurality of cooling tubes housing the electrical conductors connecting two adjacent stacks together.

[0122] Subsequently, the cooling fluid within the plurality of cooling tubes are returned to the first stack to another plurality of manifolds, separated again from the electrical conductors and transferred through another plurality of isolation tubes back to another plurality of manifolds at the second stack. From this location at the manifolds at the second stack, the isolated coolant is provided to a plurality of cooling tubes housing the electrical conductors connecting the second stack and the current source.

[0123] Specifically, Figure 15 depicts eight cooling tubes configured to cool respective electrical connectors and transfer cooling fluid to the current source. These eight tubes are connected to four manifolds, each having two inlet ports and one outlet port. The four total outlet ports are configured to transfer the cooling fluid to a final manifold having four inlets and one outlet port, in which the outlet port provides a return line of the cooling fluid back to a cooling source or cooling system within the electrochemical system / plant that isconfigured to conduct a heat exchange of the cooling fluid for reuse within the cooling lines provided to the electrochemical stacks.

[0124] In addition to the example in Figure 15, Figures 16 and 17 depict additional examples of a cooling path of the cooling fluid through two electrochemical stacks arranged in series.

[0125] Within the examples depicted in Figures 12-17, the electrochemical plant may include one or more temperature sensors or probes configured to monitor the temperature of one or more electrical conductors and / or the cooling fluid associated with the one or more electrical conductors. The measured temperatures, monitored in real-time, during operation of the electrochemical plant, may be transmitted to one or more controllers or processors within the plant (see, e.g., controller 270 depicted within Figure 4). Based upon these measured temperatures, a controller may adjust a flow rate of the cooling fluid to one or more of the cooling tubes / electrical conductors to adjust the temperature. For example, if the measured temperature is above a predefined threshold temperature, the controller may be configured to increase the flow rate to the associated cooling tube / electrical conductor to assist in lowering the operating temperature of the electrical conductor. Alternatively, if the measured temperature is below (e.g., different) predefined threshold temperature, the controller may be configured to decrease the flow rate to the associated cooling tube / electrical conductor to save on associated cooling costs.

[0126] 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.

[0127] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0128] As used herein, "for example," "for instance," "such as," or "including" are meant to introduce examples that further clarify more general subject matter. Unless otherwise expressly 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.

[0129] 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.

[0130] 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. A cooling apparatus for an electrochemical system, the cooling apparatus comprising: an electrical conductor configured to provide power to at least one electrochemical stack of the electrochemical system; and a component having a hollow channel in fluid communication with the electrical conductor, wherein the component is configured to receive a liquid coolant and cool the electrical conductor during operation of the electrochemical system.

2. The cooling apparatus of claim 1, wherein the liquid coolant comprises process water from a cooling system within the electrochemical system.

3. The cooling apparatus of claim 1, wherein the liquid coolant is provided from a cooling source external to the electrochemical system.

4. The cooling apparatus of claim 1, wherein the liquid coolant comprises water, propylene glycol, mineral oil, or combinations thereof.

5. The cooling apparatus of claim 4, wherein the water comprises process water from a cooling system within the electrochemical system, reverse osmosis deionized (ROID) water, demineralized water, sea water, or combinations thereof.

6. The cooling apparatus of any of claims 1-5, wherein the component is a hollow tube.

7. The cooling apparatus of claim 6, wherein the electrical conductor is a composition of the hollow tube.

8. The cooling apparatus of claim 7 , wherein the composition comprises copper metal.

9. The cooling apparatus of any of claims 1-5, wherein the component is a hollow flexible cable.

10. The cooling apparatus of any of claims 1-5, wherein the electrical conductor is an electrical cable, and wherein at least a portion of the electrical cable is positioned within the hollow channel of the component.

11. The cooling apparatus of claim 10, wherein the electrical cable is a co-axial flexible wire.

12. The cooling apparatus of claim 10, wherein the portion of the electrical cable is positioned within an inner tube that is surrounded by the component having the hollow channel, such that the liquid coolant is configured to flow between an outer surface of the inner tube and an inner surface of the component having the hollow channel.

13. The cooling apparatus of any of claims 1-5, wherein at least a portion of the electrical conductor abuts an outer surface of the component.

14. The cooling apparatus of any of claims 1-5, wherein the hollow channel of the component comprises a plurality of extrusion tubes having hollow passages configured to receive the liquid coolant.

15. The cooling apparatus of claim 14, wherein the plurality of extrusion tubes comprises the electrical conductor.

16. The cooling apparatus of any of claims 1-5, further comprising: a terminal having a first opening and a second opening; and a liquid coolant piping connector, wherein the first opening receives an end of the component, and wherein the second opening receives the liquid coolant piping connector for transferring the liquid coolant into or from the hollow channel of the component.

17. The cooling apparatus of any of claims 1-5, further comprising: a terminal connected to an outer surface of the component at one end of the component; and a liquid coolant piping connector connected to an opening at the one end of the component, wherein the liquid coolant piping connector is configured to receive the liquid coolant and transfer the liquid coolant into the one end of the component.

18. An electrochemical system comprising: at least one electrochemical stack, wherein each electrochemical stack of the at least one electrochemical stack comprises a plurality of electrochemical cells; at least one power supply configured to provide power to the at least one electrochemical stack; a first electrical conductor connecting the at least one power supply to a first electrochemical stack of the at least one electrochemical stack at a first terminal; a second electrical conductor connecting the at least one power supply to the first electrochemical stack or an additional electrochemical stack positioned in series with the first electrochemical stack at a second terminal; at least one first component, each first component having a hollow channel in fluid communication with the first electrical conductor, wherein the at least one first component is configured to receive a liquid coolant and cool the first electrical conductor during operation of the electrochemical system; and at least one second component, each second component having a hollow channel in fluid communication with the second electrical conductor, wherein the at least one secondcomponent is configured to receive the liquid coolant from the first electrochemical stack or the additional electrochemical stack and cool the second electrical conductor during the operation of the electrochemical system.

19. The electrochemical system of claim 18, wherein the first terminal is a positive terminal, and wherein the second terminal is a negative terminal.

20. The electrochemical system of claim 18, further comprising: a cooling system configured to provide the liquid coolant to the at least one electrochemical stack, wherein the liquid coolant comprises process water.

21. The electrochemical system of claim 20, wherein the cooling system is further configured to provide the liquid coolant to one or more additional modules within the electrochemical system, wherein the one or more additional modules comprise a power supply module, an anode / cathode gas separation module, a hydrogen product processing module, a feed water treatment module, a process water heat exchange and pumping module, or a combination thereof.

22. The electrochemical system of claim 18, wherein the liquid coolant is received from a cooling source external to the electrochemical system.

23. The electrochemical system of claim 18, wherein the liquid coolant comprises water, propylene glycol, mineral oil, or combinations thereof.

24. The electrochemical system of claim 23, wherein the water comprises process water from a cooling system within the electrochemical system, reverse osmosis deionized (ROID) water, demineralized water, sea water, or combinations thereof.

25. The electrochemical system of any of claims 18-24, wherein the at least one first component and the at least one second component are hollow tubes.

26. The electrochemical system of claim 25, wherein the first electrical conductor and the second electrical conductor are compositions of the hollow tubes.

27. The electrochemical system of claim 26, wherein the compositions comprise copper metal.

28. The electrochemical system of any of claims 18-24, wherein the at least one first component and the at least one second component are hollow flexible cables.

29. The electrochemical system of any of claims 18-24, wherein the first electrical conductor and the second electrical conductor are electrical cables, wherein at least a portion of the first electrical conductor is positioned within the hollow channel of the at least one first component, and wherein at least a portion of the second electrical conductor is positioned within the hollow channel of the at least one second component.

30. The electrochemical system of claim 29, wherein the electrical cables are co-axial flexible wires.

31. The electrochemical system of claim 29, wherein the portion of the first electrical conductor is positioned within a first inner tube that is surrounded by the at least one first component, such that the liquid coolant is configured to flow between an outer surface of the first inner tube and an inner surface of the at least one first component having the hollow channel, and wherein the portion of the second electrical conductor is positioned within a second inner tube that is surrounded by the at least one second component, such that the liquidcoolant is configured to flow between an outer surface of the second inner tube and an inner surface of the at least one second component having the hollow channel.

32. The electrochemical system of any of claims 18-24, wherein at least a portion of the first electrical conductor abuts an outer surface of the at least one first component, and wherein at least a portion of the second electrical conductor abuts an outer surface of the at least one second component.

33. The electrochemical system of any of claims 18-24, wherein the hollow channel of the at least one first component comprises a plurality of extrusion tubes having hollow passages configured to receive the liquid coolant, and wherein the hollow channel of the at least one second component comprises a plurality of extrusion tubes having hollow passages configured to receive the liquid coolant.

34. The electrochemical system of claim 33, wherein the plurality of extrusion tubes of the at least one first component comprises the first electrical conductor, and wherein the plurality of extrusion tubes of the at least one second component comprises the second electrical conductor.

35. The electrochemical system of any of claims 18-24, further comprising: the first terminal having a plurality of first openings and a second opening; and a first liquid coolant piping connector, wherein the at least one first component comprises a plurality of first components, wherein each first opening of the plurality of first openings of the first terminal receives an end of a respective first component the plurality of first components, and wherein the second opening of the first terminal receives the first liquid coolant piping connector for transferring the liquid coolant into the hollow channels of the plurality of first components.

36. The electrochemical system of claim 35, further comprising: the second terminal having a plurality of first openings and a second opening; and a second liquid coolant piping connector, wherein the at least one second component comprises a plurality of second components, wherein each first opening of the plurality of first openings of the second terminal receives an end of a respective second component the plurality of second components, and wherein the second opening of the second terminal receives the second liquid coolant piping connector for transferring the liquid coolant from the hollow channels of the plurality of second components.

37. The electrochemical system of any of claims 18-24, wherein the at least one electrochemical stack comprises a plurality of electrochemical stacks, and wherein the electrochemical system further comprises: at least one additional electrical conductor connecting adjacent electrochemical stacks of the plurality of electrochemical stacks to each other; and at least one additional component, each additional component having a hollow channel in fluid communication with the at least one additional electrical conductor, wherein the at least one additional component is configured to receive the liquid coolant from an upstream electrochemical stack of the plurality of electrochemical stacks and cool the at least one additional electrical conductor during the operation of the electrochemical system.

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