Higher-Frequency AC Network for Remote Electrolysis Power Supply
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Solution Overview
Problem
Existing electrolysis systems face challenges in achieving reliable and cost-effective electrical connections to power supply sources, particularly in island operations and line-commutated operations, with high material costs and transmission losses due to long distances and the need for large, heavy transformers.
Innovation Solution
A plant network utilizing a higher-frequency AC grid connected to a transformer with an operating frequency above the grid frequency, allowing for efficient power transmission through a central supply line, reducing transformer size and material costs, and enabling flexible integration with various power sources like wind, photovoltaic, and hydroelectric plants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If line-commutated rectifiers are used to provide direct current for industrial-scale electrolysis processes, then electrical power can be supplied from the public grid, but harmonics are generated that load the AC grid and DC grid
Solution Approach 1:
The patent introduces an intermediary AC-AC converter stage between the public grid and the DC-DC converter. This intermediary converter transforms the grid frequency AC voltage to a different frequency AC voltage, which then feeds the electrolysis cell. This intermediate transformation eliminates the direct coupling that causes harmonics, thereby reducing grid loading while maintaining power supply capability.
2Power
If transformers with grid frequency operation are used for power transmission to electrolysis plants, then power can be transmitted from the public grid, but the transformers become large and heavy requiring significant installation space
Solution Approach 1:
The patent changes the operating frequency parameter of the transformer from standard grid frequency (50/60 Hz) to a higher frequency. By operating the transformer at elevated frequency, the magnetic flux density increases, allowing the same power transmission capability to be achieved with smaller core cross-sections and less material, thereby reducing transformer weight and installation space requirements.
3Reliability
If electrolysis plants are connected to the public power grid via standard frequency transformers, then electrical connection is established, but transmission losses increase due to long distances
Solution Approach 1:
The patent employs higher frequency operation of the transformer to enable more efficient power transmission over long distances. The increased frequency allows for better utilization of the transmission line capacity and reduces reactive power losses, thereby minimizing energy loss during transmission from the public grid to remote electrolysis plants while maintaining reliable electrical connection.
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
This configuration reduces transmission losses, minimizes transformer size and installation space, and allows for flexible, scalable, and cost-effective connections to multiple electrolysis plants, supporting island grid operations with green hydrogen production.
Implementation Method 1
a transformer (7), which is dimensioned for an operating frequency above the grid frequency of the public power grid
Implementation Method 2
Hydrogen is nowadays produced, for example, from water by means of proton exchange membrane (PEM) electrolysis, an anion exchange membrane or alkaline electrolysis. The electrolysis plants produce hydrogen and oxygen from the supplied water with the aid of electrical energy.
Data Source
AI summary
A system network includes at least two electrolysis systems, a power supply source, and a central supply line. The central supply line is connected to the secondary side of a transformer. The primary side of the transformer can be fed with energy from the power supply source. The transformer is designed for an operating frequency above the mains frequency of the public power grid, and so a higher-frequency AC grid is formed, to which the electrolysis systems are connected via the central supply line.