Hybrid Electrolysis Plant Active Passive DC Module Control
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Solution Overview
Problem
Hydrogen production plants face challenges in efficiently controlling hydrogen output due to the high cost of active rectifier modules and the uncontrolled power output of passive rectifier modules, leading to undesired behavior during ramp-up and ramp-down phases.
Innovation Solution
A method utilizing a combination of active and passive DC modules in hydrogen production plants, where an active DC module powers a first electrolysis system and a passive DC module powers a second electrolysis system, allowing for controlled ramp-up and ramp-down phases by switching between them based on predefined hydrogen output thresholds, thereby maintaining a consistent overall hydrogen output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If passive rectifier modules are used, then cost is reduced, but power output becomes uncontrolled leading to undesired behavior
Solution Approach 1:
The patent combines passive rectifier modules and active rectifier modules in a hybrid configuration within the same electrolysis system. Passive modules provide cost-effective base capacity while active modules provide controllable power adjustment, achieving both cost reduction and maintained controllability through the synergistic combination of different rectifier types.
2Ease of operation
If active rectifier modules are used, then power output controllability is improved, but cost increases significantly
Solution Approach 1:
The electrolysis system is segmented into multiple rectifier modules with different control characteristics. Instead of using a single active rectifier for the entire system, the patent divides the rectification capacity into passive modules (for fixed power output) and active modules (for controllable power output), reducing the total cost while maintaining necessary controllability.
Solution Approach 2:
The patent changes the control parameter of individual rectifier modules dynamically. During ramp-up and ramp-down phases, active rectifier modules adjust their power output parameters to maintain overall system controllability. During steady-state operation, passive rectifier modules operate at fixed parameters to reduce cost, while active modules provide fine-tuned control when needed.
3Ease of operation
If only active DC modules are used, then hydrogen output controllability is improved, but component costs increase
Solution Approach 1:
The patent merges passive DC modules and active DC modules in a hybrid configuration within the same electrolysis system. Passive modules provide cost-effective base capacity while active modules provide controllable power adjustment, achieving both cost reduction and maintained controllability through the synergistic combination of different DC module types.
4Ease of manufacture
If only passive DC modules are used, then component costs are reduced, but power output becomes uncontrolled
Solution Approach 1:
The DC module system is segmented into multiple modules with different control characteristics. Instead of using a single active DC module for the entire system, the patent divides the DC conversion capacity into passive modules (for fixed power output) and active modules (for controllable power output), reducing the total component cost while maintaining necessary power output control.
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 approach provides well-controllable hydrogen production while reducing component costs by leveraging the cost-effectiveness of passive DC modules and the controllability of active DC modules, minimizing oscillations and stress on system components.
Implementation Method 1
a first electrolysis system, comprising an active DC module and at least one first-type electrolyzer, which is configured for producing a first hydrogen output by using a first power from the active DC module
Data Source
AI summary
A method for producing hydrogen using two types of electrolysis systems, the first having an active DC module and at least one first-type electrolyzer producing a first hydrogen output by using a first power from the active DC module, and the second electrolysis system having a passive DC module and at least one second-type electrolyzer producing a second hydrogen output by using a second power from the passive DC module. The method includes increasing the first hydrogen output and when it crosses a first predefined hydrogen output threshold, switching on the second electrolysis system and decreasing the first hydrogen output of the first electrolysis system to the first predefined hydrogen output threshold minus the second hydrogen output, so that an overall hydrogen output of the hydrogen production plant is a sum of the first hydrogen output and the second hydrogen output.