3D SIM 8040 Green Hydrogen Production

This Green Hydrogen Production is an 18 MW Proton Exchange Membrane (PEM) electrolysis plant, powered by renewable energy to generate high-purity, dry hydrogen gas.  

The system produces up to 4000 Nm3/h of green hydrogen by splitting demineralised water into hydrogen and oxygen using 16 electrolysis stacks  

With this Interactive 3D model, users can explore the electrolysis process, power electronics, pressure swing adsorption, and the economics of hydrogen production from renewable energy. 

See live process simulation information in the virtual environment as well as experience one of the technologies touted as part of the solution to the energy transition problem. 

Key Features: PEM Electrolysis System: 

Core Process: In this electrolysis method, electricity divides water into hydrogen and oxygen gases. A solid polymer electrolyte enables selective passage of hydrogen ions, keeping the gases isolated. 

Electrochemical Reactions: 

• At the Anode: Water breaks down, producing oxygen, hydrogen ions, and electrons: 2H₂O → 4H⁺ + O₂ + 4e⁻ 

• At the Cathode: Hydrogen ions combine with electrons to form hydrogen gas:  

4H⁺ + 4e⁻ → 2H₂ 

Electrolysis Stack Composition: Made up of numerous cells, each with bipolar plates functioning as anodes and cathodes. These plates also contain channels for water flow and gas separation. 

Operating Mechanism: 

Water enters via flow channels, moves through a diffusion layer, and reaches the anode catalyst. Here, it decomposes into oxygen gas and hydrogen ions. The hydrogen ions migrate through the membrane, reacting at the cathode to produce hydrogen gas. This process is maintained at pressures of 30 barg on the hydrogen side and 4 barg on the oxygen side. 

Cooling Integration: Circulating feed water is cooled through a heat exchanger before entering the electrolysis stack, where it serves as both a reactant and cooling agent. 

Separation and Recirculation: 

• The oxygen-water mixture separates, allowing the oxygen to vent while the water recycles through the system. 

• Similarly, the hydrogen-water mixture is cooled, separated, and purified via a pressure swing adsorption (PSA) unit, which dries the hydrogen for higher purity. 

Product Dehydration: A Temperature Swing Adsorption unit, featuring four zeolite-filled beds, further purifies hydrogen by removing residual moisture and impurities, ensuring a high purity output. 

Electrical Supply System: High voltage electricity is first stepped down and rectified to provide stable current to the electrolysis stacks, allowing precise control of hydrogen production levels. 

• Understand the principles of hydrogen production using electrolysis. 
• Understand the half-reactions that occur within a PEM electrolysis cell. 
• Understand the electrical potentials in the system and how they affect the performance and efficiency of electrolysis cell. 
• Understand the effect of the voltage, current, and number of cells on hydrogen production and stack efficiency. 
• Understand the ancillary equipment needed to produce high purity hydrogen from a PEM electrolysis system. 
• Understand the principles of temperature swing adsorption. 
• Understand why multiple adsorbers are required and how they operate to produce a continuous supply of hydrogen. 
• Analyse the economics of producing hydrogen in an electrolysis plant. 
• Understand how an electrolysis plant is configured 
• Understand how an electrolysis plant is operated by carrying out startup and shutdowns.