Alkaline Electrolyzer Cell Configuration for High-Pressure Hydrogen Production
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Solution Overview
Problem
Existing PEM-based electrolyzer configurations fail to meet DOE 2012 goals for cost, efficiency, and power density, particularly in producing hydrogen at $/kW, $/gge, and efficiency targets.
Innovation Solution
A high power density, low-cost alkaline electrolyzer configuration utilizing laminar flow forced recirculation and advanced materials like G-10 fiberglass and Ni-200 electrodes, capable of operating at up to 200 bar pressure, achieving 81% efficiency and reducing production costs to <$333/kW and $0.96/gge H2.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If PEM-based electrolyzer configurations are used, then hydrogen production capability is achieved, but cost exceeds DOE 2012 goals ($400/kW target)
Solution Approach 1:
The patent transitions from PEM technology to alkaline electrolysis, fundamentally changing the chemical parameters and operating conditions. This parameter change enables the use of less expensive materials and construction methods while maintaining hydrogen production capability, achieving costs below the DOE 2012 target of $400/kW
Solution Approach 2:
The patent employs simpler, less expensive materials in the alkaline electrolyzer construction compared to PEM systems. By using readily available materials and simplified cell designs, the system achieves lower manufacturing costs while maintaining adequate performance and lifespan for the application
2Quantity of substance
If existing electrolyzer configurations are used, then hydrogen production is achieved, but efficiency falls short of DOE 2012 goals (69% target)
Solution Approach 1:
The patent optimizes operating parameters including temperature, pressure, and electrolyte composition to maximize efficiency. By carefully controlling these parameters and using alkaline chemistry instead of PEM, the system achieves efficiencies exceeding the DOE 2012 target of 69%
3Ease of operation
If conventional electrolyzer designs are used, then operation is achieved, but power density is insufficient for high-performance applications
Solution Approach 1:
The patent employs a flat-panel cell design that maximizes active electrode area within a compact footprint. This dimensional optimization, combined with optimized flow channels and electrode structures, achieves high power density suitable for high-performance fuel cell applications while maintaining ease of operation
4Device complexity
If low-pressure electrolysis is used, then simplicity is maintained, but ability to supply high-pressure hydrogen for fuel cells is insufficient
Solution Approach 1:
The patent integrates the electrolysis function with high-pressure gas generation capability in a single system design. By optimizing the cell structure and operating conditions, the system simultaneously achieves operational simplicity and the ability to deliver hydrogen at pressures up to 200 bar, eliminating the need for separate compression equipment in many applications
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The configuration significantly enhances power density and efficiency while reducing costs, enabling the production of hydrogen and oxygen gases at high pressures for use in fuel cells and energy storage, meeting or exceeding DOE 2012 goals with a projected cost of $0.96/kg H2, a 2.6-fold reduction below the target.
Implementation Method 1
An Alkaline Electrolyzer Cell Configuration (AECC) is disclosed which achieves high efficiency by use of laminar flow forced recirculation
Implementation Method 2
An Alkaline Electrolyzer Cell Configuration (AECC) is disclosed which achieves high efficiency by use of laminar flow forced recirculation
Data Source
AI summary
An Alkaline Electrolyzer Cell Configuration (AECC) has a hydrogen half cell; an oxygen half cell; a GSM (Gas Separation Membrane); two inner hydrogen half cell spacer screens; an outer hydrogen half cell spacer screen; a hydrogen electrode; two inner oxygen half cell spacer screens; an outer oxygen half cell spacer screen; and an oxygen electrode. The hydrogen half cell includes the hydrogen electrode which is located between said two inner hydrogen half cell spacer screens and said outer hydrogen half cell spacer screen. The oxygen half cell includes the oxygen electrode which is located between said two inner oxygen half cell spacer screens and said outer oxygen half cell spacer screen. The GSM is provided between said two inner hydrogen half cell spacer screens of the hydrogen half cell and said two inner oxygen half cell spacer screens of the oxygen half cell to from the electrolyzer.