Wind-Powered Hydrogen Dispatch System with Modular DC-DC Conversion
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Solution Overview
Problem
Current electrolyser systems for industrial hydrogen production using wind power face inefficiencies due to the use of SCR rectifiers, which have low efficiency and high harmonics at varying power levels, leading to high capital costs and energy losses, and lack effective power dispatch and control systems to match wind farm output with electrolyser module requirements.
Innovation Solution
A system that includes power determination and monitoring means, transmission lines, central step-down transformers, non-regulated n-pulse rectifiers, n-pulse DC buses, and regulated DC-DC converters to distribute and regulate power to electrolyser modules, along with alternative loads and power sources to manage power imbalances, ensuring efficient and flexible power dispatch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If SCR rectifiers are used to convert AC to DC for electrolyser systems, then power conversion is achieved, but efficiency drops significantly at varying power levels and harmonics increase
Solution Approach 1:
The power conversion system is segmented into multiple independent DC-DC converter modules, each capable of operating efficiently at different power levels. Instead of using a single SCR rectifier that must handle the entire power range, the system divides the conversion function across multiple modular units that can be independently controlled and optimized for their specific operating points.
Solution Approach 2:
The system employs dynamic power management where DC-DC converters continuously adjust their operating parameters based on real-time wind farm output conditions. This dynamic adaptation allows the electrolyser system to maintain high efficiency across the full range of variable wind power generation, unlike static SCR rectifier systems.
2Productivity
If multiple electrolyser modules are used to capture high percentage of wind power, then productivity increases, but system complexity and power dispatch requirements increase
Solution Approach 1:
The DC bus serves multiple functions simultaneously: it acts as a common electrical connection for all electrolyser modules, a power distribution network, and a buffer for balancing supply and demand. This multi-functional design simplifies the overall system architecture by eliminating the need for separate complex control systems for each module.
Solution Approach 2:
The system implements feedback control where the central controller continuously monitors wind farm output and electrolyser module demands, then automatically adjusts power distribution to maintain balance. This closed-loop control simplifies power dispatch by using real-time data to automate decision-making, reducing the complexity of managing multiple modules.
3Ease of manufacture
If central step-down transformers and non-regulated rectifiers are used, then capital costs are reduced, but power regulation capability is lost
Solution Approach 1:
DC-DC converters are introduced as intermediary devices between the non-regulated rectifier output and the electrolyser modules. These converters provide the necessary power regulation and adaptation functions that simple rectifiers cannot perform, enabling the system to use cost-effective non-regulated rectifiers while still achieving precise power control at the module level.
Solution Approach 2:
The system replaces traditional mechanical or analog voltage regulation methods with electronic DC-DC conversion. This substitution allows for more precise and flexible power control while maintaining simplicity in the overall architecture, as electronic converters can be controlled through software and sensors rather than complex mechanical systems.
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 solution achieves high efficiency and low harmonics over a wide range of power levels, reducing capital costs and energy losses, and effectively matches wind farm output with electrolyser module demands, maximizing hydrogen production while maintaining grid stability.
Implementation Method 1
at least one central step down n-pulse transformer located proximate to said plurality of electrolyser modules for receiving said medium to high voltage AC electricity from said transmission lines and transforming it to low voltage AC electricity
Implementation Method 2
at least one central non-regulated n-pulse rectifier for receiving said low voltage AC electricity from said at least one central step down n-pulse transformer and converting it to non-regulated low voltage DC electricity
Implementation Method 3
at least one regulated n-pulse DC-DC converter associated with each of said plurality of electrolyser modules, each of said regulated n-pulse DC to DC converters connected to one of said at least one n-pulse DC bus, for receiving said non-regulated low voltage DC electricity from said one of said at least one n-pulse DC bus and supplying regulated DC electricity to each of said plurality of electrolyser modules
Implementation Method 4
Water electrolysers are the most common type of electrolyser used to produce gaseous hydrogen. Oxygen also is an important industrial gas, and the oxygen generated may be a saleable product
Data Source
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AI summary
A system for distributing electric power from a wind farm generating medium to high voltage AC electricity to multiple electrolyser modules for producing hydrogen. A system for distributing electric power from a wind farm generating medium voltage DC electricity to multiple electrolyser modules for producing hydrogen.