Description:FIELD OF INVENTION
[0001] Embodiments of the present disclosure relate to the field of electrochemical processes, and more particularly to, system and method to control concentration of hydrogen in oxygen during electrolysis process of water or other electrolytes.
BACKGROUND
[0002] The electrolysis of water is a well-established method for producing hydrogen and oxygen gases, involving an electrolyser that separates water into hydrogen at the cathode and oxygen at the anode through the application of an electrical current. This process typically employs a membrane to separate the cathode and anode, thereby ensuring that the gases remain distinct for safe collection and storage. Despite these precautions, some mixing of hydrogen and oxygen inevitably occurs due to gas permeation through the membrane and the intermixing of dissolved gases during electrolyte recirculation. This presents a significant safety risk, as hydrogen concentrations exceeding 4% in oxygen can form explosive mixtures.
[0003] In conventional electrolysis systems, various methods are employed to mitigate the risks associated with hydrogen-oxygen mixing. One common approach is the use of advanced membranes designed to minimize gas permeation. However, complete elimination of hydrogen permeation into the oxygen side remains unachievable, especially under fluctuating load conditions typical of renewable energy sources. Electrolyte recirculation systems are also used to manage dissolved gases, but these can inadvertently promote the intermixing of hydrogen and oxygen, exacerbating the risk of forming explosive mixtures.
[0004] Also, the conventional electrolysis systems also rely on fixed purging mechanisms, which allow for the introduction of inert gases such as nitrogen to purge the system and reduce hydrogen concentration. This method is typically employed during startup and shutdown phases, but frequent cycling due to load fluctuations can lead to unproductive downtime and increased operational costs. Some systems attempt to control hydrogen concentration by adjusting the electrical current supplied to the electrolyser, reducing gas production rates. However, this approach does not address the fundamental issue of gas mixing and can significantly impact overall efficiency. Additionally, conventional systems often vent or store off-specification oxygen—oxygen with higher hydrogen concentration—to ensure safety, resulting in the loss of valuable oxygen gas and increased operational complexity.
[0005] Despite these measures, conventional electrolysis systems face several critical limitations. Conventional purging methods are inconsistent and not dynamically adjusted based on real-time hydrogen concentration data, leading to periods of elevated risk. Frequent purging cycles and current adjustments necessitated by fluctuating energy supplies cause significant downtime and reduce overall system efficiency. Venting off-specification gases and reliance on inert gases for purging lead to resource wastage and increased operational costs. Persistent safety concerns remain due to the risk of explosive hydrogen-oxygen mixtures under variable operating conditions, particularly when integrating renewable energy sources with inherent variability.
[0006] Hence, there is a need for an improved system and method to control concentration of hydrogen in oxygen during electrolysis process, which addresses the aforementioned issue(s).
OBJECTIVE OF THE INVENTION
[0007] An objective of the present invention is to provide a system that dynamically controls the concentration of hydrogen in oxygen within an electrolyser, thereby significantly reducing the risk of forming explosive hydrogen-oxygen mixtures.
[0008] Another objective of the present invention is to implement a control subsystem with real-time monitoring and feedback mechanisms that continuously analyse hydrogen concentration data and adjust the flow of diluent gas accordingly.
[0009] Another objective of the present invention is to minimize downtime and improve overall system efficiency by reducing the need for frequent purging cycles and current adjustments typically necessitated by fluctuating energy supplies.
[00010] Another objective of the present invention is to optimize the use of resources by incorporating a storage unit for recycled oxygen gas with acceptable hydrogen levels, thus reducing the need to vent off-specification gases and decreasing reliance on inert gases for purging.
[00011] Another objective of the present invention is to utilize existing infrastructure more effectively by enabling the dual-use of purge lines for both traditional purging and diluent gas injection, thereby minimizing the need for additional hardware.
[00012] Another objective of the present invention is to ensure the electrolyser system can adapt to the variable load conditions associated with renewable energy sources, maintaining safety and efficiency even under fluctuating operational scenarios.
[00013] Another objective of the present invention is to enhance the separation of hydrogen and oxygen gases by employing advanced membrane technology and precise control mechanisms, further minimizing gas permeation and intermixing.
[00014] Another objective of the present invention is to reduce operational costs associated with gas venting, purging, and frequent maintenance by implementing a more efficient and responsive system for hydrogen concentration control.
[00015] Another objective of the present invention is to decrease the environmental impact of the electrolysis process by improving the recycling and utilization of gases, thus contributing to more sustainable hydrogen and oxygen production.
[00016] Another objective of the present invention is to design a system that is scalable and easily integrable with existing electrolysis infrastructure and renewable energy systems, promoting widespread adoption and enhancing the overall hydrogen economy.
BRIEF DESCRIPTION
[00017] In accordance with an embodiment of the present disclosure, a system to control concentration of hydrogen in oxygen during electrolysis process. The system includes an electrolyser with an oxygen side and a hydrogen side, separated by a membrane. The system also includes a diluent gas injection assembly which includes a diluent gas injection line configured to introduce a diluent gas into the oxygen side of the electrolyser. The diluent gas injection assembly also includes a control valve within the diluent gas injection line. The system also includes a hydrogen concentration sensor located on the oxygen side of the electrolyser. The system also includes a control subsystem configured to receive real-time data from the hydrogen concentration sensor; to analyse the hydrogen concentration data to determine the required flow rate of the diluent gas; and to adjust the control valve to regulate the flow of the diluent gas based on the analysed hydrogen concentration data. the system also includes an integrated feedback loop within the control subsystem to continuously monitor and adjust the injection of the diluent gas. The system further includes a purge line connected to the oxygen side of the electrolyser, wherein the control subsystem can also utilize the purge line for injecting the diluent gas.
[00018] In accordance with another embodiment of the present disclosure, a method for controlling concentration of hydrogen in oxygen during an electrolysis process is provided. The method includes measuring the concentration of hydrogen in the oxygen on the oxygen side of an operating electrolyser using a hydrogen concentration sensor. The method also includes determining a required flow rate of a diluent gas based on the measured concentration of hydrogen in the oxygen. The method also includes injecting a diluent gas into the oxygen side of the electrolyser through a diluent gas injection line, wherein the diluent gas is selected from the group consisting of oxygen, nitrogen, carbon dioxide, helium, and argon. The method further includes adjusting the flow of the diluent gas using a control valve in the diluent gas injection line, regulated by a control subsystem based on the analysed hydrogen concentration data. the method further includes utilizing an integrated feedback loop within the control subsystem for continuously monitoring the hydrogen concentration and dynamically adjusting the injection of the diluent gas. The method also includes recycling oxygen gas with acceptable levels of hydrogen back into the oxygen side of the electrolyser to act as the diluent gas, using a storage unit for the recycled oxygen gas. The method also includes injecting the diluent gas through an existing purge line connected to the oxygen side of the electrolyser as an alternative or supplementary pathway. The method also includes controlling the rate of injection of the diluent gas based on the current feed into the electrolyser, as well as the measured hydrogen concentration. The method also includes ensuring the concentration of hydrogen in the oxygen remains below a predetermined safety threshold throughout the operation of the electrolyser.
[00019] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[00020] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[00021] FIG. 1a illustrates a schematic representation of injecting diluent gas into an oxygen side of an electrolyser through a diluent injection line, in accordance with an embodiment of the present disclosure;
[00022] FIG. 1b illustrates a schematic representation of injecting diluent gas into the oxygen side of the electrolyser through an existing purge line; and
[00023] FIG. 2 illustrates a flow chart representing the steps involved in a method for controlling concentration of hydrogen in oxygen during an electrolysis process in accordance with an embodiment of the present disclosure.
[00024] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[00025] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[00026] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[00027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[00028] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[00029] Embodiments of the present disclosure relate to the field of electrochemical processes, and more particularly to, system and method to control concentration of hydrogen in oxygen during electrolysis process of water or other electrolytes. The system includes an electrolyser with an oxygen side and a hydrogen side, separated by a membrane. The system also includes a diluent gas injection assembly which includes a diluent gas injection line configured to introduce a diluent gas into the oxygen side of the electrolyser. The diluent gas injection assembly also includes a control valve within the diluent gas injection line. The system also includes a hydrogen concentration sensor located on the oxygen side of the electrolyser. The system also includes a control subsystem configured to receive real-time data from the hydrogen concentration sensor; to analyse the hydrogen concentration data to determine the required flow rate of the diluent gas; and to adjust the control valve to regulate the flow of the diluent gas based on the analysed hydrogen concentration data. the system also includes an integrated feedback loop within the control subsystem to continuously monitor and adjust the injection of the diluent gas. The system further includes a purge line connected to the oxygen side of the electrolyser, wherein the control subsystem can also utilize the purge line for injecting the diluent gas.
[00030] FIG. 1a illustrates a schematic representation of injecting diluent gas into an oxygen side of an electrolyser through a diluent injection line, in accordance with an embodiment of the present disclosure. The system (100) includes an electrolyser (110) with an oxygen side (120) and a hydrogen side (130), separated by a membrane. The electrolyser (110) at the core of this system (100) includes of an oxygen side (120) and a hydrogen side (130) which is separated by a high-performance membrane. This membrane is critical for maintaining the separation of the generated gases, preventing the intermixing of hydrogen and oxygen, which could lead to dangerous conditions.
[00031] In one embodiment, on the oxygen side (120), water molecules are oxidized to produce oxygen gas and protons. The oxygen gas may be collected for various applications, while the protons migrate through the membrane to the hydrogen side (130). On the hydrogen side (130), the protons are reduced to form hydrogen gas. This gas may also be collected for storage or further use. The separation of gases by the membrane ensures that high-purity hydrogen and oxygen are produced.
[00032] In one specific embodiment, the membrane may be a critical component that separates the oxygen and hydrogen sides (120, 130). It may be typically made from advanced materials such as proton exchange membranes (PEMs), which allow protons to pass through while acting as a barrier to the hydrogen and oxygen gases. This high selectivity is crucial for maintaining the separation of the gases and minimizing cross-contamination. The membrane's material and structure are optimized to provide high ionic conductivity and durability, ensuring efficient and long-term operation of the electrolyser (110).
[00033] The system (100) also includes a diluent gas injection assembly (140) which includes a diluent gas injection line (150) configured to introduce a diluent gas into the oxygen side (120) of the electrolyser (110). In one embodiment, the diluent gas injection line (150) may be a dedicated diluent gas injection line (150), wherein the diluent gas injection line (150) may be a dedicated conduit, distinct from other gas or fluid lines within the electrolyser (110). This ensures that the introduction of the diluent gas is controlled and not influenced by other processes.
[00034] The diluent gas injection assembly (140) also includes a control valve (160) within the diluent gas injection line (150). In one embodiment, the control valve (160) may be a high-precision valve, which may be a responsive valve within the injection line that regulates the flow rate of the diluent gas. This valve may be capable of rapid adjustments based on real-time control signals, ensuring precise control of gas flow.
[00035] In one exemplary embodiment, the diluent gas injection assembly (140) may be Connected to a source of diluent gas, such as nitrogen, helium, or recycled oxygen with acceptable hydrogen levels. The supply includes regulators to maintain the appropriate pressure and purity of the diluent gas. The endpoint of the injection line may be located on the oxygen side (120) of the electrolyser (110). This port may be designed to ensure effective mixing and dispersion of the diluent gas within the oxygen.
[00036] In such embodiment, the injection line and control valve (160) may be integrated with the electrolyser’s (110) central control subsystem, which monitors hydrogen concentration and sends real-time control signals to adjust the valve.
[00037] Furthermore, the system (100) includes a hydrogen concentration sensor (170) located on the oxygen side (120) of the electrolyser (110). In one embodiment, the sensor may employ advanced hydrogen detection technology, such as a catalytic bead sensor, metal oxide semiconductor sensor, or electrochemical sensor. These technologies may be chosen for their high sensitivity and accuracy in detecting low concentrations of hydrogen gas. In another embodiment, the sensor may be positioned on the oxygen side (120) of the electrolyser (110) where the oxygen gas is collected. This placement may be critical as it directly monitors the hydrogen concentration in the oxygen stream, ensuring timely detection of any increase in hydrogen levels.
[00038] In such embodiments, the core component of the sensor may be the sensing element, which reacts with hydrogen molecules. In catalytic bead sensors, this may involve a catalytic reaction that changes the resistance of the sensing element. In metal oxide sensors, hydrogen molecules interact with the sensor surface, altering its electrical conductivity.
[00039] In one specific embodiment, the sensor may include a signal processing unit that converts the physical changes detected by the sensing element into electrical signals. This unit processes the raw data to provide accurate readings of hydrogen concentration. Further, to maintain accuracy over time, the sensor may be equipped with an automated calibration mechanism. This feature may ensure that the sensor readings remain reliable and accurate, compensating for any drift or environmental changes.
[00040] The system (100) further includes a control subsystem configured to receive real-time data from the hydrogen concentration sensor (170). The control subsystem is also configured to analyse the hydrogen concentration data to determine the required flow rate of the diluent gas. The control subsystem is further configured to adjust the control valve (160) to regulate the flow of the diluent gas based on the analysed hydrogen concentration data.
[00041] Further the system (100) includes an integrated feedback loop within the control subsystem to continuously monitor and adjust the injection of the diluent gas.
[00042] In one embodiment, the control subsystem may include a processing unit which may be the brain of the control subsystem and may be equipped with a high-performance processor that handles real-time data processing and control algorithms. It may ensure quick and accurate analysis of the incoming hydrogen concentration data.
[00043] In another embodiment, the system (100) may feature a dedicated data interface for continuous sensor data reception, memory and storage modules for data logging, and a user-friendly interface for operators. The communication module ensures network connectivity for remote monitoring and control.
[00044] Further, the system’s real-time data acquisition capabilities may allow for continuous monitoring of hydrogen levels, while its analysis algorithms provide precise, immediate assessments of hydrogen concentration. Based on this analysis, the control algorithms may calculate an optimal flow rate of the diluent gas and send control signals to adjust the control valve (160), ensuring dynamic and accurate regulation of gas flow. In such embodiment, the feedback loop may ensure that hydrogen concentrations remain within safe limits, with rapid adjustments made to counter any increases.
[00045] In yet another embodiment, the system (100) may include safety mechanisms such as threshold alarms and support efficient resource management by minimizing waste. Its proactive hazard management may enhance safety, and its ability to maintain optimal hydrogen levels ensures continuous and efficient electrolyser (110) operation. The modular design may allow for scalability and easy integration, making the control subsystem a crucial component in modern electrolysis systems.
[00046] The system (100) also includes a purge line connected to the oxygen side (120) of the electrolyser (110), wherein the control subsystem can also utilize the purge line for injecting the diluent gas. In one embodiment, the purge line may be a dedicated conduit constructed from materials resistant to the corrosive effects of oxygen and other gases, ensuring durability and reliability. In one exemplary embodiment, integrated within the purge line is a high-precision control valve (160) which may regulates the flow of gases, allowing for controlled purging and accurate injection of diluent gas as dictated by the control subsystem. The line may be fully integrated with the electrolyser’s (110) control subsystem, enabling seamless management of its functions, including switching between purging and diluent gas injection modes.
[00047] In another embodiment, the purge line may be connected to a source of purge gas, typically an inert gas like nitrogen, and to the diluent gas supply. An automated switching mechanism within the control subsystem may determine when the purge line should be used for purging versus diluent gas injection, based on real-time sensor data and the operational status of the electrolyser (110). Sensors monitor the hydrogen concentration in the oxygen side (120), informing the control subsystem when to activate the purge line for diluent gas injection to maintain safe hydrogen levels. Additional flow sensors ensure the correct volume of gas is purged or injected.
[00048] In operation, the system (100) operates meticulously within the electrolysis process, where water undergoes decomposition into hydrogen and oxygen gases via electrochemical reactions. Its functioning is intricate, aiming to meticulously regulate the concentration of hydrogen within the oxygen stream to curtail safety hazards and optimize operational efficacy.
[00049] Central to the system's (100) operation is the diluent gas injection assembly (140), which constitutes a specialized pathway dedicated to introducing the diluent gas into the oxygen side (120) of the electrolyser (110). This assembly is equipped with a finely-tuned control valve (160) strategically positioned within the injection line, allowing for granular control over gas flow rates, contingent upon real-time data insights.
[00050] The continuous surveillance of hydrogen concentration is facilitated by a meticulously positioned sensor stationed on the oxygen side (120) of the electrolyser (110). This sensor serves as the sentinel, transmitting critical data to the control subsystem, which serves as the nerve centre of the system (100). Embellished with a robust processing unit and a sophisticated communication module, the control subsystem orchestrates dynamic adjustments to the diluent gas flow, ensuring a delicate equilibrium whereby hydrogen concentration is rigorously maintained within permissible limits.
[00051] An ingenious feedback loop, seamlessly integrated within the control subsystem, fortifies the system's (100) operational prowess by enabling proactive hazard management. This loop acts as the vigilant overseer, promptly responding to fluctuations in hydrogen concentration by effecting real-time adjustments to diluent gas injection, thereby pre-empting potential safety risks.
[00052] Moreover, the system (100) ingeniously repurposes the existing purge line, tethered to the oxygen side (120) of the electrolyser (110), as an alternative conduit for diluent gas injection. This ingenious adaptation circumvents the need for additional hardware while augmenting the system's (100) versatility and efficiency.
[00053] Further enhancing operational efficiency is an innovative recycling mechanism, meticulously designed to reclaim oxygen gas possessing acceptable hydrogen levels and reintroduce it into the oxygen side (120) of the electrolyser (110). This recycled oxygen, serving as an efficacious diluent gas, plays a pivotal role in attenuating hydrogen concentration, thereby optimizing resource utilization and bolstering system efficiency.
[00054] In essence, the system (100) orchestrates a sophisticated ballet of gas dynamics, meticulously adjusting diluent gas injection rates based on real-time data insights to uphold stringent safety standards and maximize operational performance throughout the electrolysis process. Through its intricate operational framework, the system (100) emerges as a stalwart guardian, ensuring the seamless interplay of safety, efficiency, and resource optimization in electrolysis operations.
[00055] FIG. 1b illustrates a schematic representation of injecting diluent gas into the oxygen side (120) of the electrolyser (110) through an existing purge line. Here, the process may commence with the identification of the existing purge line, a pre-existing infrastructure designed to facilitate the removal of inert gases, typically nitrogen, from the electrolyser (110). Leveraging this infrastructure for dual functionality, the system (100) ingeniously repurposes the purge line to serve as an alternative pathway for introducing diluent gas into the oxygen side (120) of the electrolyser (110).
[00056] Upon activation, the control subsystem orchestrates a seamless transition, redirecting the flow of diluent gas towards the designated entry point within the oxygen side (120) of the electrolyser (110). This entry point, strategically positioned to ensure optimal dispersion and mixing of the diluent gas within the oxygen stream, serves as the nexus for injecting the diluent gas into the electrolyser (110).
[00057] The control valve (160), intricately integrated within the purge line, assumes a pivotal role in regulating the flow of diluent gas with unparalleled precision. Responding to real-time data insights gleaned from the hydrogen concentration sensor (170), the control subsystem orchestrates meticulous adjustments to the control valve (160), fine-tuning the diluent gas flow rates to maintain hydrogen concentration within permissible limits.
[00058] Simultaneously, the system (100) remains cognizant of the electrolyser's (110) operational dynamics, factoring in the current feed to the electrolyser stack as a determinant for optimizing diluent gas injection rates. This holistic approach ensures a harmonious interplay between operational exigencies and safety imperatives, culminating in the meticulous management of hydrogen concentration throughout the electrolysis process.
[00059] Through this ingenious operational framework, the system (100) maximizes the utilization of existing infrastructure, minimizing the need for additional hardware while enhancing operational versatility. By repurposing the purge line as a conduit for diluent gas injection, the system (100) epitomizes efficiency, seamlessly integrating safety protocols with operational imperatives to uphold stringent standards in electrolysis operations
[00060] FIG. 2 illustrates a flow chart representing the steps involved in a method for controlling concentration of hydrogen in oxygen during an electrolysis process in accordance with an embodiment of the present disclosure. The method (200) includes measuring the concentration of hydrogen in the oxygen on the oxygen side of an operating electrolyser using a hydrogen concentration sensor in step 210. More specifically, the concentration of hydrogen within the oxygen on the oxygen side of an actively running electrolyser is quantified. This quantification may be achieved through the utilization of a specialized device known as a hydrogen concentration sensor. Positioned strategically within the oxygen side of the electrolyser, this sensor functions to detect and measure the concentration of hydrogen gas present within the oxygen stream. Through its precise sensing capabilities, the hydrogen concentration sensor provides crucial real-time data, enabling the control subsystem to monitor and regulate the hydrogen concentration effectively throughout the electrolysis process.
[00061] The method (200) also includes determining a required flow rate of a diluent gas based on the measured concentration of hydrogen in the oxygen in step 220. More specifically, the method (200) may calculate the necessary rate at which a diluent gas should be introduced into the oxygen side of the electrolyser. This determination is made by analysing the previously measured concentration of hydrogen within the oxygen stream. By assessing the hydrogen concentration data obtained from the hydrogen concentration sensor, the system can ascertain the appropriate flow rate of the diluent gas required to maintain the hydrogen concentration within safe levels. This calculated flow rate ensures that the mixture of gases remains within acceptable limits, mitigating the risk of explosive hydrogen-oxygen combinations during the electrolysis process.
[00062] Further, the method (200) includes injecting a diluent gas into the oxygen side of the electrolyser through a diluent gas injection line, wherein the diluent gas is selected from the group consisting of oxygen, nitrogen, carbon dioxide, helium, and argon in step 230. More specifically, the method (200) involves the introduction of a diluent gas into the oxygen side of the electrolyser via a designated diluent gas injection line. The choice of diluent gas is flexible and can be selected from a range of options, including oxygen, nitrogen, carbon dioxide, helium, and argon. By utilizing this injection mechanism, the system can effectively regulate the composition of gases within the electrolysis process, thereby controlling the concentration of hydrogen in the oxygen. This injection process plays a crucial role in maintaining safe operating conditions and preventing the formation of explosive mixtures within the electrolyser.
[00063] Furthermore, the method (200) includes adjusting the flow of the diluent gas using a control valve in the diluent gas injection line, regulated by a control subsystem based on the analysed hydrogen concentration data in step 240. More specifically, the method (200) may involve fine-tuning the flow of the diluent gas through a control valve integrated into the diluent gas injection line. This adjustment is managed by a control subsystem, which utilizes the analysed data on hydrogen concentration within the oxygen side of the electrolyser. Based on this data, the control subsystem dynamically regulates the opening or closing of the control valve, thus controlling the rate at which the diluent gas is injected into the electrolyser. By continuously monitoring and responding to changes in hydrogen concentration, this process ensures that the composition of gases remains within safe thresholds, optimizing the efficiency and safety of the electrolysis process.
[00064] The method (200) also includes utilizing an integrated feedback loop within the control subsystem for continuously monitoring the hydrogen concentration and dynamically adjusting the injection of the diluent gas in step 250. More specifically, the method (200) incorporates an integrated feedback loop within the control subsystem to maintain continuous surveillance of the hydrogen concentration within the electrolyser. This feedback loop continuously receives data from the hydrogen concentration sensor, allowing the control subsystem to dynamically adjust the injection of the diluent gas in response to any fluctuations in hydrogen concentration. By constantly monitoring and adapting the diluent gas injection based on real-time hydrogen concentration data, the system ensures precise control and maintains the hydrogen concentration within safe levels throughout the electrolysis process.
[00065] The method (200) also includes recycling oxygen gas with acceptable levels of hydrogen back into the oxygen side of the electrolyser to act as the diluent gas, using a storage unit for the recycled oxygen gas in step 260. More specifically, the method (200) involves recycling oxygen gas that meets acceptable hydrogen concentration levels back into the oxygen side of the electrolyser to serve as the diluent gas. This recycled oxygen gas, which acts as the diluent, is stored in a designated storage unit. By reusing oxygen gas with suitable hydrogen levels, the system optimizes resource utilization and minimizes the need for external sources of diluent gases, contributing to efficiency and sustainability in the electrolysis process.
[00066] Furthermore, the method (200) injecting the diluent gas through an existing purge line connected to the oxygen side of the electrolyser as an alternative or supplementary pathway in step 270. More specifically, the method (200) introduces the diluent gas into the oxygen side of the electrolyser through an existing purge line, offering an alternative or supplementary pathway for injection. By utilizing the existing infrastructure of the purge line, the system enhances flexibility and efficiency in controlling the concentration of hydrogen in the oxygen. This approach optimizes resource utilization and minimizes the need for additional hardware, streamlining the electrolysis process.
[00067] Furthermore, the method (200) includes controlling the rate of injection of the diluent gas based on the current feed into the electrolyser, as well as the measured hydrogen concentration in step 280. More specifically, the rate of injection of the diluent gas is regulated based on both the current feed into the electrolyser and the measured hydrogen concentration in the oxygen. By considering these two variables simultaneously, the system ensures precise control over the diluent gas injection, maintaining optimal conditions within the electrolysis process. This dynamic adjustment helps to prevent unsafe levels of hydrogen concentration and promotes efficient operation of the electrolyser.
[00068] The method (200) also includes ensuring the concentration of hydrogen in the oxygen remains below a predetermined safety threshold throughout the operation of the electrolyser in step 290. More specifically, here the primary objective is to maintain the concentration of hydrogen in the oxygen below a predetermined safety threshold consistently during the operation of the electrolyser. By continuously monitoring and adjusting the injection of diluent gas, the system ensures that the hydrogen concentration remains within safe limits, mitigating the risk of potential hazards such as explosions due to high concentrations of hydrogen. This proactive approach enhances the safety and stability of the electrolysis process.
[00069] Various embodiments of the present invention offer several advantages. The foremost advantage lies in its proactive safety measures. By continuously monitoring and regulating the concentration of hydrogen in the oxygen produced during electrolysis, the system ensures that it remains below predetermined safety thresholds. This proactive approach minimizes the risk of hazardous conditions or explosions, thus enhancing overall operational safety. Another key benefit is its capability for continuous operation. Unlike conventional methods that necessitate halting the electrolysis plant when hydrogen concentration levels exceed safety limits, this system allows for uninterrupted operation even at varying loads. By dynamically adjusting the injection of diluent gas in response to real-time data, it reduces downtime due to safety concerns, thereby boosting productivity.
[00070] Efficient resource utilization is also facilitated by the system's ability to recycle oxygen gas with acceptable hydrogen levels back into the electrolyser as diluent gas. This not only minimizes reliance on external sources for diluent gas but also conserves energy and reduces costs associated with gas procurement.
[00071] Moreover, the system offers flexibility and adaptability by allowing operators to choose from a range of diluent gases, including oxygen, nitrogen, carbon dioxide, helium, or argon. This flexibility enables customization of the dilution process according to specific operational requirements or resource availability.
[00072] Integrated control and monitoring further enhance system efficiency. With an integrated feedback loop and control subsystem, the system continuously monitors hydrogen concentration levels and dynamically adjusts the injection of diluent gas as needed. This ensures precise control over the electrolysis process, optimizing both performance and safety simultaneously.
[00073] Lastly, the system is particularly beneficial for electrolysis plants powered by renewable energy sources like wind or solar. By stabilizing hydrogen concentration levels, it mitigates the challenges posed by fluctuating energy supply, enabling more consistent and efficient production of hydrogen and oxygen. This maximizes the utilization of renewable energy resources and contributes to a more sustainable energy ecosystem.
[00074] The techniques described in this disclosure may be implemented, at least in part, in hardware, software, firmware, or any combination thereof. For example, various aspects of the described techniques may be implemented within one or more processors, including one or more microprocessors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or any other equivalent integrated or discrete logic circuitry, as well as any combinations of such components. The term “processor” or “processing subsystem” may generally refer to any of the foregoing logic circuitry, alone or in combination with other logic circuitry, or any other equivalent circuitry. A control unit including hardware may also perform one or more of the techniques of this disclosure.
[00075] Such hardware, software, and firmware may be implemented within the same device or within separate devices to support the various techniques described in this disclosure. In addition, any of the described units, modules, or components may be implemented together or separately as discrete but interoperable logic devices.
[00076] Depiction of different features as modules or units is intended to highlight different functional aspects and does not necessarily imply that such modules or units must be realized by separate hardware, firmware, or software components. Rather, functionality associated with one or more modules or units may be performed by separate hardware, firmware, or software components, or integrated within common or separate hardware, firmware, or software components.
[00077] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[00078] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[00079] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:1. A system (100) to control concentration of hydrogen in oxygen during electrolysis process, wherein the system (100) comprising:
an electrolyser (110) with an oxygen side (120) and a hydrogen side (130), separated by a membrane;
characterised in that,
a diluent gas injection assembly (140), comprising:
a diluent gas injection line (150) configured to introduce a diluent gas into the oxygen side (120) of the electrolyser (110);
a control valve (160) within the diluent gas injection line (150);
a hydrogen concentration sensor (170) located on the oxygen side (120) of the electrolyser (110);
a control subsystem configured to:
receive real-time data from the hydrogen concentration sensor (170);
analyse the hydrogen concentration data to determine the required flow rate of the diluent gas; and
adjust the control valve (160) to regulate the flow of the diluent gas based on the analysed hydrogen concentration data;
an integrated feedback loop within the control subsystem to continuously monitor and adjust the injection of the diluent gas; and
a purge line connected to the oxygen side of the electrolyser (110), wherein the control subsystem can also utilize the purge line for injecting the diluent gas.
2. The system (100) as claimed in claim 1, wherein the diluent gas is selected from the group consisting of oxygen, nitrogen, carbon dioxide, helium, and argon.
3. The system (100) as claimed in claim 1, wherein the control subsystem adjusts the flow of the diluent gas based on the current feed to the electrolyser (110).
4. The system (100) as claimed in claim 1, wherein the diluent gas is injected through the purge line.
5. The system (100) as claimed in claim 1, comprising a storage unit (180) for recycled oxygen gas with acceptable levels of hydrogen, wherein the control subsystem recycles the stored oxygen gas back into the oxygen side (120) of the electrolyser (110) as the diluent gas.
6. A method (200) for controlling concentration of hydrogen in oxygen during an electrolysis process, comprising:
measuring the concentration of hydrogen in the oxygen on the oxygen side of an operating electrolyser using a hydrogen concentration sensor; (210)
determining a required flow rate of a diluent gas based on the measured concentration of hydrogen in the oxygen; (220)
injecting a diluent gas into the oxygen side of the electrolyser through a diluent gas injection line, wherein the diluent gas is selected from the group consisting of oxygen, nitrogen, carbon dioxide, helium, and argon; (230)
adjusting the flow of the diluent gas using a control valve in the diluent gas injection line, regulated by a control subsystem based on the analysed hydrogen concentration data; (240)
utilizing an integrated feedback loop within the control subsystem for continuously monitoring the hydrogen concentration and dynamically adjusting the injection of the diluent gas; (250)
recycling oxygen gas with acceptable levels of hydrogen back into the oxygen side of the electrolyser to act as the diluent gas, using a storage unit for the recycled oxygen gas; (260)
injecting the diluent gas through an existing purge line connected to the oxygen side of the electrolyser as an alternative or supplementary pathway; (270)
controlling the rate of injection of the diluent gas based on the current feed into the electrolyser, as well as the measured hydrogen concentration; and (280)
ensuring the concentration of hydrogen in the oxygen remains below a predetermined safety threshold throughout the operation of the electrolyser. (290)
7. The method (200) as claimed in claim 6, wherein measuring the concentration of hydrogen in the oxygen using a hydrogen concentration sensor comprises measuring the concentration of the hydrogen via the hydrogen concentration sensor in real-time for analysing and adjusting of the diluent gas flow.
8. The method (200) as claimed in claim 6, comprising optimizing the injection of the diluent gas based on historical data and predicted electrolysis conditions using a control module.
9. The method (200) as claimed in claim 6, comprising calibrating the hydrogen concentration sensor periodically to ensure accurate measurement and control.

Dated this 25th day of June 2024

Signature

Jinsu Abraham
Patent Agent (IN/PA-3267)
Agent for the Applicant