Description:FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION: “AN ALKALINE WATER ELECTROLYZER FOR PRODUCTION OF HYDROGEN AND METHOD FOR OPERATING THE SAME”
2. APPLICANT:

(a) NAME : Greenzo Energy India Limited
(b) NATIONALITY : India
(c) ADDRESS : Unit No.: 1104/19, 11th Floor
Surya Kiran Building
K. G. Marg
Connaught Place 110 001
New Delhi INDIA
3. PREMABLE TO THE DESCRIPTION
PROVISIONAL

The following specification describes the invention. ?COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
The field of invention relates to the electrochemical system. More particularly, the present invention relates to an alkaline water electrolyzer for achieve the optimum amount of hydrogen at the output.
BACKGROUND OF THE INVENTION
Electrolyzers are essential devices for generating hydrogen and oxygen gases through the electrolysis of electrolyte solution—a process in which electrical energy splits electrolyte solution molecules into their elemental components. As global energy systems shift toward de-carbonization and sustainable alternatives, electrolyzers have become increasingly important for producing clean hydrogen, a flexible energy carrier with applications in energy storage, green transportation, power-to-gas conversion, and numerous industrial processes such as ammonia synthesis and steel production.
Despite their potential, current electrolyzer technologies face persistent technical and economic limitations that hinder widespread adoption. One of the most significant challenges is the absence of an optimized system that consistently achieves high-efficiency and high-output hydrogen production. Existing electrolyzer configurations, including alkaline and proton exchange membrane (PEM) systems, often exhibit suboptimal performance due to high internal resistance, poor ion conductivity, and non-uniform cell architecture. These factors result in energy losses, elevated cell voltages, and inefficient conversion of electrical energy into chemical energy. Additionally, uneven electrolyte solution and gas distribution across electrodes, gas crossover through membranes, and non-uniform current density further compromise operational safety and efficiency.
In addition, the conventional electrolyzer technology having perforated bipolar plates. Such convention electrolyzer uses KOH as the electrolytes which are highly sensitive to ambient CO2. The absorption of CO2 leads to the formation of potassium carbonate (K2CO3), which reduces the concentration of hydroxyl ions (OH?) and subsequently lowers the ionic conductivity of the electrolyte. Furthermore, the precipitated K2CO3 salts tend to block the perforation of the bipolar plates, restricting gas transport through the diaphragm and ultimately reducing hydrogen production efficiency. Additionally, said electrolyzers typically produce hydrogen with relatively low purity due to incomplete gas separation diaphragms do not fully prevent crossover of hydrogen and oxygen between half-cells.
Moreover, the hydrogen gas is produced at low pressure, and often requiring additional compression for storage or downstream utilization. This adds cost and complexity to the system and increases the total energy demand.
Therefore, there is a need for an improved electrolyzer that addresses the issues of low energy efficiency, low hydrogen output and output pressure thereof, while also enhancing the durability and integration of critical components and that overcome the difficulties as described above.
OBJECTIVE OF THE INVENTION
The main objective of the present invention is to provide the alkaline water electrolyzer that produces the optimum hydrogen production.
Another objective of the present invention is to provide the alkaline water electrolyzer that minimize blockage of flow-paths of electrolyte solution, increasing the hydrogen purity and overall efficiency of the alkaline water electrolyzer.
Another objective of the present invention is to provide the alkaline water electrolyzer that sustain the internal pressure and provide the pressurized hydrogen at the output.
Another objective of the present invention is to enhance the overall energy efficiency of alkaline water electrolyzer by minimizing internal resistance, improving thermal management, and optimizing electrochemical cell.
Another objective of the present invention is to increase the hydrogen production rate per unit of electrical energy input by reducing gas crossover and ensuring uniform fluid distribution across electrode surfaces.
Another objective of the present invention is to improve the durability and functional integration of critical stack components, particularly the bipolar plates, by utilizing corrosion-resistant and highly conductive materials.
Another objective of the present invention is to optimize the design of bipolar plate (105) flow channels and sealing mechanisms to support efficient reactant distribution, effective gas separation, and enhanced system reliability under pressurized conditions.
Another objective of the present invention is to reduce the overall operational and maintenance costs of alkaline water electrolyzer, thereby supporting their commercial viability for large-scale hydrogen production.
Another objective of the present invention is to develop a compact, modular alkaline water electrolyzer architecture that facilitates scalable deployment across a variety of energy storage, industrial, and transportation applications.
Another objective of the present invention is to provide the alkaline water electrolyzer suitable for a wide range of operational environments and operate safely in extreme conditions ranging from -20°C to 60°C, allowing for flexible deployment in diverse geographical locations.
Another objective of the present invention is to provide the alkaline water electrolyzer that consumes low electric power and operate on high operating pressure.
Another objective of the present invention is to provide alkaline water electrolyzer that allowing for both small and large-scale hydrogen production.
SUMMARY OF THE INVENTION
The present invention relates to an electrolyzer for efficient hydrogen production. The present invention comprises an electrolyzer cell stack formed by a plurality of electrochemical cells connected in series. A bipolar plate (105) separates each adjacent cell (103). Each cell includes a pair of gas diffusion layer and one of the said gas diffusion layer work as an anode electrode and other work as a cathode electrode, and a diaphragm positioned between them. Gaskets are placed around the electrodes to provide effective sealing and structural support. The present invention improves the overall efficiency and operational lifespan of the electrolyzer by optimizing gas and electrolyte solution flow management, reducing internal electrical resistance, minimizing degradation of key cell components, and ensuring consistent hydrogen output. The present invention also contributes to enhanced thermal stability and operational safety. These improvements collectively enable more reliable, durable, and cost-effective hydrogen production, making the system highly suitable for long-term industrial and renewable energy applications.

BRIEF DESCRIPTION OF THE DRAWING
Other objects, advantages and novel features of the disclosure will become apparent from the following detailed description of the present embodiment when taken in conjunction with the accompanying drawings.
Fig. 1 shows an isometric view of an electrolyzer cell stack with an exploded view of a cell, in accordance with some embodiments of the present invention;
Fig. 2 shows an exemplary flow chart related to the method for producing hydrogen gas using the electrolyzer, in accordance with some embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanied drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.
The present invention is relates to an alkaline water electrolyzer, and more particularly, an alkaline water electrolyzer for generation of the hydrogen from the electrolyte solution. In the alkaline water electrolyzer, electrolyte solution is split into hydrogen and oxygen by an electrolyzer cell stack (101).
Fig. 1 illustrates an exploded view of an electrolyzer cell stack (101), in line with certain embodiments of the present invention. The alkaline water electrolyzer comprises electrolyzer cell stack (101) is housed within a vessel (not shown) that becomes internally pressurized with gas during operation. The vessel is a horizontal cylindrical shell that accommodates the electrolyzer cell stack (101) therein. The electrolyzer cell stack (101) is assembled in between the pair of the end plate (117) through the studs (127), providing structural integrity and uniform compression across the entire electrolyzer cell stack (101). The vessel is constructed from metal or a composite material, such as a fiber-reinforced structure. Said end plates (117) are configured with the multiple inlets and outlets namely, electrolyte solution inlet (119), hydrogen outlet (123), electrolyte solution inlet (121) and oxygen outlet (125).
In an embodiment, said electrolyzer cell stack (101) comprises a multiple electrochemical cells (103) arranged in series to increase hydrogen production capacity. Each cell (103) comprises a pair the Gas Diffusion Layer (GDL) (109, 111) in which one of the GDL work as an anode electrode (109) and other work as an cathode electrode (111), a diaphragm (113) sandwiched between said pair of the Gas Diffusion Layer (GDL) (109, 111) and gaskets (115) surrounding said anode and cathode electrodes (109, 111). Each cell (103) is separated from the next one by a bipolar plate (105). Furthermore, a DC power source is connected to the electrolyzer cell stack (101), providing the electrical energy needed to drive the electrolysis reactions.
In an embodiment, the diaphragm (113) is mainly configured to ensure that hydrogen and oxygen molecules cannot pass through the diaphragm (113), but allow electrolyte ions to pass through it, enabling the electrolysis of electrolyte solution into hydrogen and oxygen. The diaphragm (113) is made from Polyphenylene Sulfide (PPS) material or a polysulfide matrix filled with zirconium oxide. The thickness of diaphragm is below the 1 mm and preferably is 0.85±0.10. It is to be construed that the size and material of the diaphragm (113) is not limited the described herein. The diaphragm (113) is also be made from material, but not be limited to, perfluorosulfonic acid (PFSA) polymers such as Nafion®, sulfonated polyether ether ketone (SPEEK), polybenzimidazole (PBI), or composite diaphragms incorporating inorganic fillers like silica, zirconia, or graphene oxide. Furthermore, said diaphragm (113) is coated or embedded with catalysts including, but not limited to, composition of nickel- phosphorus alloy. Said diaphragm (113) is able to resist corrosion from high concentration alkali solution, provides good mechanical strength, remain chemically stable under electrolysis temperature and alkaline conditions, and can withstand the impact of electrolyte solution and generated gas for a long time without damage. Furthermore, the diaphragm (113) is configured with the smaller surface resistance with high porosity, resulting reduction of the power loss.
In an embodiment, the Gas Distribution Layer (GDL) (109, 111) comprises a mechanically expanded, diamond-cut pure nickel mesh for high structural integrity and efficient gas transport. Said GDL provides excellent electrical conductivity and corrosion resistance in alkaline media (e.g., 25–30 wt% KOH) and suitable for high-pressure electrolyzer operation (= 32–45 bar). The mesh having ~3 mm diamond-shaped openings with ~1.2 mm strand gaps, enabling directional gas flow while maintaining mechanical strength. The thickness of the GDL is preferably 0.4 to 0.6 mm with a low porosity (<1%), the GDL acts as anode electrode (109), cathode electrode (111), and a semi-permeable gas distributor, resulting effectively removing evolved gases (hydrogen at the cathode, oxygen at the anode) and preventing bubble accumulation that could disrupt reaction kinetics. The structured geometry maintains stable three-phase boundary conditions by ensuring continuous electrolyte contact without flooding the catalyst layer. Serving as current collector, the mesh ensures uniform current distribution, minimal resistance, and sustained alignment. The GDL provides laminar gas movement and defines clear pathways for gas evolution, minimizing dead zones and enhancing overall electrolyzer performance.
Said diaphragm (113) and electrodes (109, 111) are assembled through a hot pressing and cold pressing process which involving the application of controlled pressure conditions with the temperature of 400°C and -20°C respectively for compressing process. Said assembling process also involves the air circulation to effective compression of the diaphragm and electrodes. Said pressing processes enhance interfacial contact between the diaphragm and the electrode layers, thereby minimizing interfacial resistance and improving the overall structural integrity. This reduction in contact resistance leads to lower ohmic losses during operation, thereby increasing the efficiency and electrochemical performance of the electrochemical cell (103).
The bipolar plate (105) is made from nickel coated stainless steel or mild steel corrosion-resistant materials. It is to be construed that the material of the bipolar plate (105) is not limited to describe herein. The bipolar plate (105) is also being made from material, but not limited to, titanium or steel alloy or mild steel. The bipolar plate (105) is mounted between each cell (103) of the electrolyzer cell stack (101), serving as both electrical conductors and gas separators. These bipolar plates (105) are typically assembled using laser welding, which ensures precise, strong, and leak-proof joints critical for maintaining the integrity of the stack under high pressure and corrosive conditions. The bipolar plate (105) also facilitates uniform distribution of electrolyte solution and gases while minimizing electrical resistance across the stack.
Said bipolar plate (105) has flow field channels (Not shown) configured to distribute electrolyte solution across the anode electrode (109) and cathode electrode (111) sides of each cell (103). Said flow field channels are engraved over the surface of the bipolar plates (105) in a serpentine path manner. It is to be understood that the path shape of flow filed channel is not limited to describe herein. The path of the flow filed channel may form in other shapes such as straight, spiral and like. The flow field channel is connected the electrolyte solution inlet (119, 121) such that the electrolyte solution can flow from the electrolyte solution inlet (119), contacting the surface of the electrodes (109, 111) by flowing through the flow field channels. In such configuration of bipolar plates (105), the electrolyte solution, gas, and dissolved salts like K2CO3 are forced to flow through flow field channels, directing the fluid across the electrodes (109, 111). Such configuration ensures precise control of flow path and velocity, preventing dead zones where K2CO3 could concentrate and crystallize. The flow field channels create shear forces and turbulence, which help keep salts dissolved and enable effective flushing of any forming deposits.
The bipolar plate (105) also acts as current collectors, maintaining electrical contact between adjacent cells (103) to allow the efficient flow of electrons throughout the electrolyzer cell stack (101). Each bipolar plate (105) is electrically connected in series manner, allowing the voltage of each cell to add up. Further, said bipolar plate (105) ensures that the electrochemical reactions at both the anode electrode (109) and cathode electrode (111) are balanced and optimized. The connection between the bipolar plate (105) and the electrodes (109, 111) is achieved using gaskets (115), preferably made from materials, but not limited to, Polytetrafluoroethylene (PTFE) or Ethylene Propylene Diene Monomer (EPDM) rubber, which prevent gas crossover between cells (103) and provide a secure, leak-tight system. Said gasket (115) may further prevent short circuit between conductive parts, provide the uniform pressurized support to the electrode, bipolar plates, GDL and diaphragm.
In an embodiment, said bipolar plate (105) used in the electrolyzer cell stack (101) are manufactured with specific dimensions to ensure optimal performance and structural integrity. A first set of bipolar plates (105) has a diameter of 1400mm and a thickness of 12.6 mm. said bipolar plates (105) are arranged in the stack with 148 plates inserted between the each adjacent cell (103) of the electrolyzer cell stack (101). Said first set configuration of the bipolar plates (105) produce 100 nm3 to 200 nm3 hydrogen. In similar manner, the second set of bipolar plate (105) is manufactured with a diameter of 1034 mm and a thickness of 12.6 mm, with 94 bipolar plates (105) inserted between each adjacent cell (103) of the electrolyzer cell stack (101). Said second set configuration of the bipolar plates (105) produce 50 nm3 hydrogen. The third set of bipolar plate (105) is manufactured with a diameter of 2000 mm and a thickness of 16 mm, with 256 bipolar plates (105) inserted between each adjacent cell (103) of the electrolyzer cell stack (101). Said third set configuration of the bipolar plates (105) produce 1000 nm3 hydrogen. The bipolar plates (105) are configured to facilitate efficient gas distribution, current conduction, and separation of the electrochemical reactions while maintaining structural support throughout the electrolyzer cell stack (101). The number of bipolar plates (105) and dimensions of the bipolar plates (105), inserted in between the electrolyzer cell stack (101) may vary depending on the required performance and specifications of the alkaline water electrolyzer.
In an embodiment, a DC power source is connected to the electrolyzer cell stack (101), providing the electrical energy needed to drive the electrolysis reactions. The bipolar plates (105) of middle cell of an electrolyzer cell stack (101) is connected with the positive terminal of the DC power source and the bipolar plates (105) of both ends of an electrolyzer cell stack (101) is connected with the negative terminal of the DC power source. The electrical connection to the stack (101) is made through bus bars or terminals, which allow the stack to receive a constant DC current. The bipolar plates (105) act as current collectors, transmitting the electrical current between adjacent cells (103). The power supply is typically regulated by a controller to ensure that the voltage and current are optimized for the electrolysis process. Proper regulation is critical to achieving efficient electrolyte solution splitting and hydrogen production while minimizing energy losses.
In an embodiment, the electrolyte solution comprises, but not limited to, an aqueous solution of about 20 wt % to about 40 wt.%, or about 30 wt %, potassium hydroxide (KOH) or sodium hydroxide (NaOH), although any number of other ionic solutions may be used. For example, the electrolyte solution contains lithium hydroxide or other metals. Said electrolyte solution is inserted in the electrolyzer cell stack (101) through the electrolyte solution inlet (119) through the pump, in pressurized manner.
Electrolyte solution supplied to the anode electrode (109) side of each cell (103) through flow field channels within the bipolar plates (105) and electrolyte solution inlet (119, 121), ensuring even distribution across the surface of anode electrode (109). The electrolyte solution undergoes electrolysis, generating oxygen at the anode electrode (109). On the cathode electrode (111) side, hydrogen gas is produced and collected. The oxygen produced at the anode electrode (109) and hydrogen produced at cathode electrode (111) is vented out through the oxygen outlet (125) and hydrogen outlet (123) respectively. The configuration of the bipolar plates (105) in alkaline water electrolyzer sustains the internal pressure 35-40bar. Further, said configuration of alkaline water electrolyzer generates the hydrogen at the 30-32 bar pressure and reduce the power consumption to 4.0 KWh to 4.7 KWh for generation of 1 nm3 hydrogen.
Additionally, the alkaline water electrolyzer comprises safety and control components such as pressure relief valves, temperature sensors, flow meters, and backpressure regulators. These components are integrated into the alkaline water electrolyzer to monitor operating conditions and prevent overpressure, overheating, or gas crossover. Such configurations ensure the system operates safely and within the desired parameters. The electrolyzer cell stack (101) is designed to operate under carefully controlled conditions, with sensors providing real-time data to ensure that electrolyte solution, temperature, pressure, and gas flow are all maintained at optimal levels. These systems work in tandem with the power supply to ensure stable and efficient operation of the alkaline water electrolyzer.
In a method, the electrolysis process within the alkaline water electrolyzer begins when pressurized electrolyte solution is introduced to the anode electrode (109) side of the electrochemical cells (103) in the stack through the electrolyte solution inlet (119, 121). Said electrolyte solution is pressurized by using the pump. Said electrolyte solution is delivered through the flow field channels in the bipolar plates (105), ensuring uniform distribution across the anode electrode (109). Once the electrolyte solution reaches the anode electrode (109), a DC power source is activated, supplying the necessary electrical energy to drive the electrochemical reaction. The positive terminal of the DC power source is connected to the anode electrode (109), and the negative terminal is connected to the cathode electrode (111) and forms an external circuit.
At the anode electrode (109), the hydroxide ions (OH?) from the alkaline electrolyte undergo oxidation to generate oxygen gas (O2), water (H2O), and electrons. The oxidation reaction at the anode electrode (109) is represented by the following equation:
4OH? ? O2 + 2H2O + 4e? ….. equation (1)
This reaction releases oxygen gas (O2) at the anode electrode (109) and produces electrons (e-), which are essential for the continuation of the electrolysis process.
Once the electrons (e-) are produced at the anode electrode (109), they migrate through the external circuit connected between the anode electrode (109) and cathode electrode (111). This flow of electrons generates a current that can be utilized for external applications, such as powering devices or storing energy. The flow of electrons through the circuit is an essential part of the process as it helps maintain electrical continuity and drives the reduction reaction at the cathode electrode (111).
At the cathode (111), water molecules accept electrons and are reduced to produce hydrogen gas (H2) and hydroxide ions. The reduction reaction that occurs at the cathode electrode (111) can be represented by the following equation:
2H2O + 2e? ? H2 + 2OH? ….. equation (2)
This reaction produces hydrogen gas (H2) at the cathode electrode (111). The hydrogen gas is collected and stored as per standard and can be used for various applications.
Meanwhile, the bipolar plates (105) positioned between each cell (103) play a vital role in maintaining the integrity of the electrochemical process. These plates act as both current collectors and gas separators. The flow field channels within the bipolar plates (105) are designed to ensure the uniform distribution of electrolyte solution, hydrogen, and oxygen across the anode electrode (109) and cathode electrode (111) sides of each cell (103). This distribution maximizes the efficiency of the electrochemical reaction and ensures that the gas produced at the anode electrode (109) and cathode electrode (111) is properly separated. The bipolar plates (105) also conduct electrical current between adjacent cells (103), helping to maintain electrical continuity across the entire stack. The configuration of the bipolar plates (105) in alkaline water electrolyzer sustains the internal pressure 35-40 bar. Further, said configuration of alkaline water electrolyzer generates the hydrogen at the 30-32 bar pressure and reduce the power consumption to 4.0 KWh to 4.7 KWh for generation of 1 nm3 hydrogen.
The bipolar plates (105), in conjunction with gaskets (115) made from materials like PTFE or EPDM rubber, create a leak-tight seal between the cells (103), preventing any gas crossover between the hydrogen and oxygen produced. This sealing ensures that the gases remain separated, preventing dangerous mixtures of hydrogen and oxygen. The gaskets (115) also provide compression to the stack, ensuring that the cells (103) are uniformly compressed and operate at optimal performance.
Finally, the electrolysis reaction continues as long as the DC power is supplied to the stack. The process is cyclic, with electrolyte solution continuously being split into hydrogen and oxygen, which are then collected and separated through the bipolar plates (105). The alkaline water electrolyzer is designed to operate efficiently under high-pressure and corrosive conditions, with the laser welding of the bipolar plates (105) ensuring that all joints are precise, strong, and leak-proof. This ensures the overall structural integrity of the system while maintaining high electrochemical performance.
The electrolysis process within the alkaline water electrolyzer involves the splitting of electrolyte solution molecules into hydrogen and oxygen gases. This process is driven by the application of electrical energy from a DC power source, with the bipolar plates (105), diaphragm (113), and gaskets (115) to ensure efficient gas separation and electron flow. The alkaline water electrolyzer having the bipolar plates (105) sustains the internal pressure 35-40 bar. Further, said configuration of alkaline water electrolyzer generates the hydrogen at the 30-32 bar pressure and reduce the power consumption to 4.0 KWh to 4.7 KWh for generation of 1 nm3 hydrogen. The system allows for continuous hydrogen production with high efficiency, making it ideal for a wide range of applications, including clean energy generation and industrial hydrogen production.
The invention has been explained in relation to specific embodiment. It is inferred that the foregoing description is only illustrative of the present invention and it is not intended that the invention be limited or restrictive thereto. Many other specific embodiments of the present invention will be apparent to one skilled in the art from the foregoing disclosure. All substitution, alterations and modification of the present invention which come within the scope of the following claims are to which the present invention is readily susceptible without departing from the spirit of the invention. The scope of the invention should therefore be determined not with reference to the above description but should be determined with reference to appended claims along with full scope of equivalents to which such claims are entitled.

REFERENCE NUMERALS

101 Electrolyzer cell stack
103 Cell
105 Bipolar plate (105)
109 Gas diffusion layer (GDL)/ Anode electrode
111 Gas diffusion layer (GDL) / Cathode electrode
113 Diaphragm/separator
115 Gaskets
117 End plate
119 Electrolyte solution inlet
121 Electrolyte solution inlet
123 Hydrogen outlet
125 Oxygen outlet
127 Stud , Claims:We Claim:
1. An alkaline water electrolyzer for hydrogen production, comprising
an electrolyzer cell stack (101) having plurality of cells (103) connected in series; a bipolar plate (105) to separate each adjacent cell (103);
said each cell (103) comprises
a pair of Gas Diffusion Layer (GDL) (109, 111); one of said GDL act as an anode electrode (109) and other act as a cathode electrode (111);
a diaphragm (113) disposed between the anode electrode (109) and the cathode electrode (111) and configured to permit selective ion transport;
a gaskets (115) disposed around the electrodes (109, 111) and a Direct Current (DC) power source electrically connected across the electrolyzer cell stack (101);
an end plate (117) assembled at the each end of the electrolyzer cell stack (101) through studs (127); said end plate (117) having an electrolyte solution inlet (119, 121) to supply electrolyte solution to at least one of the anode electrode (109) or the cathode electrode (111) of the cell (103), a hydrogen outlet (123) and an oxygen outlet (125) configured to collect hydrogen gas from the cathode electrode (111) and oxygen gas from the anode electrode (109) respectively;
said bipolar plate (105) having a nickel coating to enhance electrochemical reaction efficiency.
2. The alkaline water electrolyzer as claimed in claim 1, wherein the number of bipolar plates (105) are 148 and having a diameter of 1400mm and a thickness of 12.6 mm, or number of bipolar plates (105) are 94 and having a diameter of 1034mm and a thickness of 12.6 mm, or number of the bipolar plates (105) are 256 and having a diameter of 2000mm and a thickness of 16mm.
3. The alkaline water electrolyzer as claimed in claim 1, wherein the bipolar plate (105) is made from stainless steel material.
4. The alkaline water electrolyzer as claimed in claim 1, wherein the bipolar plate (105) having a serpentine flow field channel on a surface thereof for uniform electrolyte solution distribution and gas evacuation.
5. The alkaline water electrolyzer as claimed in claim 1, wherein the diaphragm (113) is made from Polyphenylene Sulfide (PPS) material or a polysulfide matrix filled with zirconium oxide.
6. The alkaline water electrolyzer as claimed in claim 1, wherein the anode electrode (109) and cathode electrode (111) are made from a nickel based material.
7. The alkaline water electrolyzer as claimed in claim 1, wherein the gasket is made from Polytetrafluoroethylene (PTFE) or Ethylene Propylene Diene Monomer (EPDM) rubber.
8. The alkaline water electrolyzer as claimed in claim 1, wherein the bipolar plates (105) sustain the internal pressure 30-40 bar.
9. The alkaline water electrolyzer as claimed in claim 1, wherein the alkaline water electrolyzer generates the hydrogen at the 30-32 bar pressure.
10. The alkaline water electrolyzer as claimed in claim 1, wherein the alkaline water electrolyzer reduced the power consumption to 4.0 KWh to 4.7 KWh for generation of 1 nm3 hydrogen.
11. The alkaline water electrolyzer as claimed in claim 1, wherein the GDL is made from pure nickel mesh having diamond-cut shape.
12. The alkaline water electrolyzer as claimed in claim 11, wherein the GDL mesh having 3 to 3.5 mm diamond-shaped openings with 1 to 1.2 mm strand gaps and a porosity 0.5 - 1%,
13. A method for producing hydrogen gas using the alkaline water electrolyzer, comprising:
a) introducing (201), a pressurized electrolyte solution to an anode electrode (109) side of electrolyzer cell stack (101) through the electrolyte solution inlet (119, 121), by pump;
b) applying (203), Direct Current (DC) power source through external circuit to the electrolyzer cell stack (101);
c) oxidizing (205), the electrolyte solution at the anode electrode (109) to generate oxygen gas, water, and electrons;
d) conducting (207), the electrons through an external circuit from the anode electrode (109) to the cathode electrode (111);
e) reducing (209), the water molecules at the cathode electrode (111) by combining with the electrons to form hydrogen gas and hydrogen ions;
f) collecting (211), the hydrogen gas at the cathode electrode (111) and oxygen gas at the anode electrode (109) through the hydrogen outlet (123) and oxygen outlet (125) respectively; and
g) recirculating (213) continuously pressurized electrolyte solution within an electrolyzer stack to periodic removal of generated gases from respective outlets.
14. The method as claimed in claim 13, wherein the electrolyte solution comprises an aqueous solution of about 20 wt % to about 40 wt.%, potassium hydroxide (KOH).
15. The method as claimed in claim 13, wherein a positive terminal of the DC power source is connected to the middle bipolar plate (105) of electrolyzer cell stack (101) and a negative terminal of the DC power source is connected with the bipolar plate (105) of both ends of an electrolyzer cell stack (101).