New Arrival Pem Electrolyzer

 

1. Small Footprint and Efficient Operation

Our system boasts a compact design with a focus on maximizing efficiency. It achieves this through:
- High operating current density ranging from 1.5 to 3A/cm², ensuring optimal performance within a small space.
- The core area of the tank maintains a thickness of less than 1m, allowing for a streamlined setup.
- Integration of a skid-mounted auxiliary control system enhances operational efficiency and ease of management.

2. Optimized Efficiency Standards

We prioritize efficiency in every aspect of our system, aiming to:
- Keep DC power consumption below 4.3 kWh/Nm³, ensuring economical operation.
- Attain a thermal efficiency surpassing 75%, reflecting our commitment to energy conservation.
- Utilize top-tier PEM membrane electrodes recognized on an international scale for their superior performance.

3. Versatile Expansion Capabilities

Our system is designed for seamless scalability, featuring:
- Compatibility with various assembly programs to accommodate diverse requirements.
- Tailoring options to meet the specific parameters of different tank configurations.
- Integration onto a skid-mounted platform, facilitating easy expansion and adaptation.

4. Swift Response and Adaptability

We prioritize responsiveness and adaptability to varying conditions, including:
- Achieving a hot start duration of just 5 seconds and a cold start duration of under 300 seconds, ensuring minimal downtime.
- Adapting to load variations ranging from 5% to 120%, maintaining stable performance under fluctuating demands.
- Verified performance through rigorous testing, guaranteeing reliable cyclic start/stop operations and longevity.

5. Enhanced Safety Measures

Safety is paramount in our design, incorporating:
- A self-developed dual-wire sealing design program, bolstering containment and preventing leaks.
- Multi-gas sensor monitoring with alarm interlock systems, providing real-time detection and response to potential hazards.
- Comprehensive control over pressure, temperature parameters, and hydrogen production circuit logic, ensuring ultra-safe operation at all times.

 

 

Name	Parameter
Hydrogen production capacity (Nm3/h)	200
Peak hydrogen production capacity (Nm3/h)	240
DC power consumption (kWh/Nm3)	≤4.3
Hydrogen purity (Before purification)	≥99.9%
Electrolyzer Enclosure– W x D x H(m)	0.8x0.6x1.5
Operating pressure (MPa)	3 . 0
Operating temperature (℃)	70±5
Ambient Temperature (℃)	5~40
Power consumption range	5-1 2 0 %
Cold start time (Minute)	≤5
Hot start time (Second)	5
Service life (Year)	≥5
Electrolyte	H2O
Separation Unit
Rated oxygen processing capacity	100 Nm3/h
Oxygen purity (rated operating conditions)	>99.8%(0.2 MPa);>98.5%(3 MPa)
Oxygen outlet temperature(℃)	70±5
Purification Unit
Hydrogen purity (After purification)	≥99.999%
Dew point of hydrogen	-70℃
Hydrogen outlet temperature	Ordinary temperature

 

Advantages of PEM over traditional alkaline water electrolysis for hydrogen production:

① High-purity and pollution-free

Since the solid electrolyte is used for the proton exchange membrane in PEM hydrogen production, the gas generated does not need to be dealkalized. In addition, the molecular-level microporous ion membrane is so thin that it seldom causes reverse osmosis of hydrogen. Only pure water is required for the PEM model, which involves no additives or corrosive liquid, discharging no pollution into the environment and producing high-purity hydrogen, while traditional alkaline electrolysis requires the addition of 15% NaOH or 30% KOH, making the electrolyte highly corrosive that may easily cause flushing liquid to contaminate the loading pipeline.

 

② High conversion efficiency

The catalyst layer at the electrode of the PEM model is with molecular-level micropore, which is a catalytic electrode with zero-pole distance, close to both sides of the proton membrane and between the internal pores. It is superior in terms of the large reaction area and high conversion efficiency, while the traditional alkaline electrode leaves a small distance limit between the electrodes, making the resistance between the electrodes quite great, which means a larger current, more heat, and lower conversion efficiency.

 

③ Compact weight and volume

The ion collector module of two electrolytic cells in the PEM electrolyzer is compact and elastic, making the electrolyzer light and small. It only weighs 1/3 of an ordinary electrolyzer with the same hydrogen production capacity. Its advantages include zero pole distance, and small internal resistance, while the ion collector module of the internal electrolytic cell in the traditional alkaline electrolyzer is not elastic, resulting in high heat loss of electrical energy and low conversion efficiency.

 

④ Adaptable to the fluctuating power generation from renewable energy

The PEM water electrolysis system for hydrogen production has a fast response speed and is adaptable to dynamic operation, which is applicable to the uneven, intermittent and fluctuating power transmission from renewable energy sources such as wind and solar energy.

From the technical perspective, the PEM electrolytic cell is compact in structure and size, which is more adaptable to rapid load change. The PEM electrolyzer produces high-purity hydrogen safer, more efficiently, and reliably at a lower cost of energy consumption with more adaptability to renewable energy sources, making it the most promising water electrolysis technology for hydrogen production in this regard.

 

However, the highly acidic and oxidizing operating environment required by the PEM electrolyzer makes it more dependent on precious metal materials such as Ir, Pt, and Ti, resulting in a high cost of the PEM electrolysis equipment for now, which constitutes the bottleneck restricting the development of PEM hydrogen production technology and the focus of related research and development.

 

SANY Hydrogen Energy Assembly Facility

Spanning 216 meters in length and 72 meters in width, our workshop comprises three distinct zones totaling approximately 15,000 square meters. Zone A is designated for our machine processing line scheduled for commissioning in 2024. Zone B houses a hydrogen refueling station assembly line boasting an annual capacity of 20 sets. Zone C accommodates a hydrogen production equipment assembly line capable of producing 2GW alkaline water electrolyzers annually. Construction of the entire production line commenced in January 2023 and was successfully completed, ushering into operation by March 2023, underscoring SANY's rapidity and our prowess in equipment manufacturing.

 

• Hydrogen Separation and Purification System Assembly Area

SANY's hydrogen separation and purification system is powered by our self-developed intelligent pipeline design platform, which ensures an annual production capacity of more than 160 sets. The assembly area consists of a final assembly unit and a pipeline prefabrication unit. The final assembly unit can efficiently assemble 5 sets of separation and purification systems at the same time, and the pipeline prefabrication unit involves the blanking, bending, welding and prefabrication of pipelines. The production line has 5 separation system assembly stations and 5 purification system assembly stations, independent pipeline welding stations, pipeline slope cutting and bending stations, and air tightness test stations to achieve the unified process from pipeline prefabrication, overall assembly to end-of-line testing, which is able to deliver one set of separation and purification system in 10 days.

Pipe Bender: Two sets of CNC benders are used. Currently, they can only bend 0-40 mm pipes with the accuracy of 0.05 mm. We are developing the bending technique for pipes in a larger diameter, which is planned to be put into use in 2024.

Automatic Pipeline Cutting and Beveling Line: The line consists of a pipeline feeding system, a hydraulic rotation system, a length measurement system, a cutting and beveling machine, a laser coding system, a discharging system, a material retrieval system, etc., which realizes the entirely automatic process from raw materials onto the line to finished pipelines off the line. Its processing accuracy is less than 0.5 mm. The efficiency is increased by more than 3 times, and it can handle up to Φ350mm pipes.

Pipe Bender: Two sets of CNC benders are used. Currently, they can only bend 0-40 mm pipes with the accuracy of 0.05 mm.

Automatic Pipe Welding Machine: It can automatically weld the straight pipes and straight pipes, straight pipes and bent pipes, straight pipes and tees in thickness of 2-10 mm and diameters of 0-400 mm. It uses the argon arc welding technique, which is more than three times faster than manual welding. It also greatly improves the welding quality. Currently, the first-pass rate of flaw detection exceeds 99%. The welds are processed using a weld cleaning machine imported from Germany, which allows better antioxidant capacity than that of the traditional pickling and passivation treatment. The cleaning is environmentally friendly with no waste liquid.

 

• Electrolyzer Assembly Station

The electrolyzer assembly station is made for the final assembly of electrolyzers, consisting of 5 sets in total. Each set uses a flexible design to meet the production needs of up to 3,000 Nm3/h. Each assembly station is composed of a hydraulic hoisting platform and a screw drive lifter. The hydraulic hoisting platform realizes the assembly requirements at the height of 0 to 7.5 meters, and the screw drive lifter significantly simplifies the total assembly process, which also saves a great amount of plant vertical space, eliminating the plant height limitation issue. The electrolyzer assembly process uses positioning pins and sophisticated 5-line laser leveling technique to ensure a precise stack assembly outcome (the vertical deviation of the electrolyzer to be within 5 mm). The 18-axis hydraulic tensioner completely eliminates inefficient actions such as frequent disassembly and assembly of tensile screws during the tightening process, reduces the workload on employees, and doubles the efficiency.

Electrolyzer Assembly Process:

Vertical Stacking Control Process for Large Electrolyzers: It enables the control over the stacking of bipolar plates in vertical and circumferential directions through standardized measures such as five-line levels and positioning pins. Currently, the vertical deviation of 1000 Nm³/h electrolyzers can be controlled within 5mm.

Tightening Process for Electrolyzers: The 18-axis tightening process is adopted. All parameters of the three major techniques including cold tightening, heat tightening, and final tightening are under control. The distance between hemispherical poles is evenly controlled at 0.3mm, and the overall tightening deviation is less than 3 mm.

 

• Gasket Cutter

The gasket cutter adopts an aerospace-grade aluminum honeycomb adsorption panel, by utilizing profiling tools, negative pressure vacuum and infrared calibration to achieve fixing and positioning of gaskets. During gasket processing, a combination of vibrating cutter and milling cutter is used for hole, groove and step surface processing, and the final product has an overall accuracy of 0.5 mm.

 

• Pipeline Prefabrication Area

The pipeline prefabrication area mainly consists of pipe cutting, pipe bending, pipe welding, and pipe pre-assembly. Pipe cutting involves the cutting and beveling of stainless steel pipes. The main equipment includes band saws, beveling machines, and semi-automatic cutting and beveling integrated machines, meeting the production requirements for pipe diameters ranging from 0 to 400 mm. Pipe bending is carried out using two sets of CNC bending machines to meet the bending needs of pipes ranging from 0 to 40 mm, with a bending accuracy of up to 0.05 mm. Pipe welding employs a fully automatic pipe welding machine to fulfill automatic welding requirements for straight-to-straight pipes, straight-to-bent pipes, and straight pipes to tees within the thickness range from 2 to 10 mm and diameter range from 0 to 400 mm. The use of argon arc welding technology achieves a welding speed of over three times that of manual welding. Weld seams are treated using a German-imported weld seam cleaning machine, which provides oxidation resistance surpassing traditional acid pickling and passivation processes, ensuring that the cleaning process generates no waste liquid, thus being environmentally friendly. For pipe pre-assembly, specialized combination fixtures with a positioning accuracy of 0.5 mm are utilized, meeting the assembly and positioning requirements of pipe assemblies. This facilitates offline batch pre-assembly of pipe assemblies and fulfills the requirements for online assembly, serving as a crucial step in achieving large-scale production for the separation and purification system.

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