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Article history: This paper presents an analysis of the data collected during a test of the 36 kW alkaline
Received 24 May 2010 electrolyser at West Bacon Farm (WBF), Loughborough, UK. This data is then used to verify
Received in revised form a software model of an electrolyser. The test consisted of collecting data under different
17 December 2010 operating conditions, in particular controlling the power supplied to the electrolyser.
Accepted 18 January 2011 The experiment was divided in four phases. In the first two phases, the electrolyser was
Available online 8 April 2011 operated at full power, in the third phase it was operated at 60% of maximum power and in
the forth it was operated at 20% of maximum power, which is the minimum permitted
Keywords: level. Each phase lasted approximately an hour.
Alkaline electrolyser During phase 1, the initial warm up period, the voltage remained almost constant, while
Simulation programme the current increased to a maximum of 428 A. After about an hour, the current suddenly
Experimental data dropped to 310 A, the voltage decreased from 92 V to 88 V and hydrogen production
Electrolyser model decreased from 7.3 Nm3/h to 6.6 Nm3/h, even though no change had been made to the
control parameters, which were still set to maximum power input. The temperature
continued upwards with only a slight reduction in its rate of increase and the pressure
stopped rising, remaining at 22 bar(g). This point marks the transition from phase 1 to
phase 2 and the reasons for the sudden discontinuity are investigated in this study.
Once the optimum operating temperature was reached, during phase 2, it was main-
tained within a limited range by the cooling system. The initial stack temperature, at the
beginning of phase 1, had been 17 C. The net power draw increased until the stack
temperature reached its maximum at 76 C after about 1 h 20 min.
Copyright 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights
reserved.
prevent a mixing of the product gases, the two reaction areas The experiment was divided in three phases, in corre-
are separated by a gas-tight, ion-conducting membrane. This spondence of three different levels of the supplied power: in
type of system can produce high purity hydrogen that is the first phase the power was set to the maximum level, in the
suitable for use in fuel cells (FCs) in a range of stationary, second phase a 60% maximum power was considered, during
portable or vehicular applications. the last phase 20% maximum power was supplied, taking into
account it is the minimum switching on power of the
electrolyser.
2. Validation of the electrolyser model. HARI The first phase lasted 2 h, while the other two phases kept
project about 1 h each. The whole collected data is plotted in the Fig. 1,
where the several quantities featuring the electrolyser are
This work focused on the analysis of the data acquired from reported as a function of the time from 11.00 oclock in the
the electrolyser located in the West Bacon Farm (WBF), which morning to 3.00 pm.
is part of the demonstration project carried out in Lough- During the start up, while the voltage was almost constant,
borough, in United Kingdom. The project is called HARI. The the current increased until a maximum value of 428 A,
researchers working on this project developed the system reached after 1 h 20 min. After that, even if the control system
integration of several environmental friendly innovative was not modified and it was set to the maximum value, the
technologies to supply the energy required by the WBF [6,7]. In current suddenly dropped down to 310 A. In this instant, the
particular, the activity described in this paper dealt with the voltage decreased from 92 V to 88 V, hydrogen production
electrolyser and with the analysis of the possibility to apply decreased from 7.3 Nm3/h to 6.6 Nm3/h, the temperature
a model already available in literature [8,9]. During the test, curve had a modification of the slope, the pressure reached
real data was collected from the operating 36 kW alkaline the maximum equals to 22 bar(g). After 1 h 20 min a disconti-
electrolyser. The electrolyser worked in different operating nuity was noticed and in correspondence of that point, at the
conditions and the power was varied in three steps. same time, the electricity, the voltage and the hydrogen yield
The data acquired were: dropped down, the temperature slope curve varied, the pres-
sure draw reached a maximum and after that it was stabilized
Current in Amperes at 22 bar(g). Because of this discontinuity, the analysis of the
Voltage in Volts 100% power phase has been split into two parts.
Pressure in bar(g) To process the data analysis, data from the electrolysers
Temperature in degrees Celsius internal data acquisition (DAQ) system had to be synchro-
Hydrogen produced in normal cubic metres. nized with that of the sites own DAQ system, which was
operating at a different sample rate. Once synchronised, the inside the electrolyser which switches on at a certain time.
acquired data allowed analysis of the operating conditions of The problem was to individualize what kind of control system
the electrolyser, both during the initial warm up period and switched on and why, because it was designed directly by the
during steady-state conditions at power inputs of 100%, 60% electrolyser manufacturers. Analyzing the plots in the Fig. 1,
and 20% of the maximum power. Analyzing the plots, the control system seemed to be activated by the pressure
summarized in the Fig. 1, four phases are finally individual- level. In fact, in the phase 1 the pressure increased to reach
ized, each of which had a duration of about 1 h: a certain point. After that, during the phase 2, the pressure
was constant, therefore the control system works in order to
- Phase 1: the warm up, providing 100% of the power usable by stabilize the pressure, once it joined the maximum plate
the electrolyser; value. The pressure control insured safe working conditions.
- Phase 2: the provided power was set to maximum, but the In addition, the constant pressure is suitable for conventional
electrolyser was working in steady-state conditions; electrolyser applications in industrial sector. In this kind of
- Phase 3: the input power was decreased to a value 60% of the applications an important target is to maintain a constant
maximum electrolyser working power; hydrogen flow, and it can be obtained by means of a uniform
- Phase 4: the power was supplied at 20% of the maximum pressure difference between the electrolyser and the ambient
electrolyser working power, which is the minimum oper- where the hydrogen is used.
ating level.
2.3. Phase 3
All this phases will be further discussed in detail in the
following paragraphs. For each phase, with the intent to During this phase, the current and power draws were very
eliminate some noise, the data had been averaged in the range smooth and the pressure reached the new working value,
of 1 min. equals to 18 bar(g), after about half an hour.
Excluding the warm up, in the phases 2, 3, 4 the working The hydrogen production decreased during the transition
conditions were quite stable and the averaged quantities of phase, reaching the value equals to 19.6 bar(g) when the
current, pressure, temperature, voltage, hydrogen production pressure was stabilized. Decreasing the energy provided to the
could be considered as characteristic of each phase, as electrolyser, a contemporary temperature reduction had been
reported in Table 1. recorded, because of the correspondent abatement of the heat
production inside the electrolyser. With regard to the
2.1. Phase 1 temperature, it had a wave shape between the values 67.7 C
and 73.7 C, excluding the transition phase from the 100%e
During the warm up, all the quantities increased constantly. 60% feeding power.
The hydrogen production was characterized by a disconti-
nuity after about 10 min, due to the fact the compressor 2.4. Phase 4
started to work when the pressure reached 19 bar(g). During
the warm up, the pump switched on after 7 min. Decreasing the feeding power, the attention focused on the
minimum working power required by the electrolyser. Looking
2.2. Phase 2 to the global graph reported in Fig. 1, there was a 10 min break
during which the electrolyser was switched off. It was not
After 1 h 20 min, without modifying any control system provoked by purpose, but it gave the opportunity to make some
quantity, the electrolyser changed suddenly the working considerations, with particular attention to the temperature
conditions. Albeit the data reported in Fig. 1 were averaged in which decreased from 75.6 C to 67.6 C, that means the heat
the range of 1 min, the current draw was still variable and it was quickly dispelled. By the analysis of this fact, the conclu-
had a shape pretty different from the other phases plots. sion was that if the electrolyser has to work in variable condi-
The reason of this unstable input current has been analyzed, tions, characterized by frequent switch on/off cycles, the stack
in accordance with the other quantities and considering the should be insulated to reduce the heat exchange between the
several components of the electrolyser. The attention focused stack and the ambient in order to maintain high temperature as
on the sudden variation in the electrolyser working conditions. long as possible. In variable working conditions, the system
The rising questions was why the electrolyser suddenly insulation could be a crucial aspect to be further analyzed in
changed the working conditions and all the plots had particular if Cool-Heat-Power (CHP) generating systems will be
a discontinuity in the same instant. designed in order to optimize the efficiency.
Considering that all the quantities varied in one instant, During the phase 3, the current was variable, but in
the conclusion was that there should be a control system a limited range between 102 A and 117 A. The wave shape of
Table 1 e The operating current, pressure, temperature, voltage and hydrogen production in each phase.
Phase Current (A) Pressure (bar) Temperature ( C) Voltage (V) H2 production (Nm3/h)
Fig. 2 e The cycles of the phase 4. Fig. 3 e Comparison U real and U model.
7960 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 3 6 ( 2 0 1 1 ) 7 9 5 6 e7 9 6 2
I=A2
hF f2 (2)
f1 I=A2
nc I
n_ H2 hF (3)
zF
Analyzing the graph, the first solution seems not only more
simple, considering constant parameters, but also more
similar to the real data. The differences between the real data
and the first model solution were analyzed, phase by phase.
Starting from the left side of the Fig. 4 b, the real data is
characterized by a discontinuity when the compressor
switched on. In fact, only when the hydrogen production
reached 19 bar(g), the compressor started to work. The model
does not simulate the compressor and this caused noteworthy
errors during the start up and during low power supply level,
in the phase 4 (ref. Fig. 4 c), when the compressor switches on
and off during regular intervals.
During the phase 2, the computed hydrogen production is
more variable than the real quantities, because the model
does not consider the elasticity of the gas (compression-
decompression). In fact the model considers the gas produc-
tion as a function of the supplied electricity. Also other
quantities influenced the hydrogen yield, like the temperature
and the voltage, but they had lower effects. In conclusion, the
actual range of the hydrogen flow was actually smaller than
the range foreseen by the simulation, but this last included the
first one.
During the phase 3, at the beginning there was a transition
period when the real data was higher than the simulated one.
During this stage, which has persevered for about half an
hour, the real data was characterized by a descending trend, Fig. 4 e Comparison graphs between real and model data.
while the simulated data had a constant trend. The real
behaviour was influenced by the working conditions of the
previous phase. When the stationary conditions were
reached, the calculated data was correspondent to the real averaged values of the hydrogen flow (marked by circles in the
one. Fig. 4 c) are very similar to the real ones (marked with rhom-
During the last phase, the real hydrogen yield was depen- buses). Although the moment by moment hydrogen produc-
dent on the compressor working conditions. This provoked tion was not always well foreseen by the model, the integral
a step trend of the real hydrogen flow. The model did not quantity of the produced hydrogen has been calculated in
include what was downstream the electrolyser and for this order to verify if the model values matched the real ones. The
reason the hydrogen production was almost constant, but the integral of the hydrogen yield during the whole experimental
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 3 6 ( 2 0 1 1 ) 7 9 5 6 e7 9 6 2 7961
[8] ystein U. Modelling of advanced alkaline electrolyzers: [9] Zuccari F, Santiangeli A, Artuso P, DellEra A. PV-electrolyzer
a system simulation approach. International Journal of system optimization. In: Proceedings 63 Congresso Nazionale
Hydrogen Energy 2003;28:21e33. ATI. 63 Congresso Nazionale ATI. 23e26 September 2008;
2008.