Pem Water Electrolyser

 

1. Compact Design
- High operating current density (1.5~3A/cm²)
- Core tank area thickness < 1m
- Skid-mounted integrated auxiliary control system

2. High Efficiency
- DC power consumption < 4.3 kWh/Nm³
- Thermal efficiency > 75%
- Utilizes PEM membrane electrodes of top international standard

3. Scalability
- Compatible assembly program
- Customizable for different tank parameters
- Integrated skid-mounted platform for easy expansion

4. Rapid Responsiveness
- Hot start duration: 5 seconds
- Cold start duration: < 300 seconds
- Adaptable to load variations of 5-120%
- Verified cyclic start/stop performance and longevity

5. Enhanced Safety Features
- Dual-wire self-developed sealing design
- Multi-gas sensor monitoring with alarm interlock
- Pressure, temperature, and hydrogen production circuit logic control for added safety.

 

 

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

 

PEM water electrolysis technology is similar to PEM fuel cell technology, where a sulfonated polymer membrane can be used as the electrolyte. The ionic charge carriers H+ and DI water (deionized water) through the proton-conducting membrane to provide energy for the electrochemical reaction. Typically, PEM water electrolysis operates at lower temperatures (30-80℃) at higher current densities (1-2 A/cm2), and produces high-purity (99.999%) gases (hydrogen and oxygen).

 

Due to the highly active area on the metal surface of Pt-based electrodes and the lower pH value of the electrolyte, the kinetics of PEM electrolysis in the hydrogen evolution reaction is faster than that of alkaline electrolysis. In addition, PEM electrolysis does not contain caustic alkaline electrolytes, which ensures smaller footprint and better safety than alkaline electrolysis.

 

SANY Hydrogen Energy Assembly Workshop

 

The workshop stretches 216 meters long and 72 meters wide, of which three zones cover an area of about 15,000 square meters in total. Zone A is a reserved space for our machine processing line that is planned to be put into use in 2024. Zone B is a hydrogen refueling station assembly line with an annual capacity of 20 sets of hydrogen refueling stations. Zone C is a hydrogen producing equipment assembly line with an annual capacity of 2GW alkaline water electrolyzers. The construction of the entire production line started in January 2023, and was completed and put into use in March 2023, which reflected the speed of SANY and also our advantages in the field of equipment manufacturing.

 

 

①Welding Robot Work Station

Available in September 2023, and independently developed by the SANY Robotics R&D team, the welding robot work station consists of a truss unstacking system, a robotic handling system, a laser welding system, a visual recognition system, and a bipolar plate flipping system. In every 5 minutes, a bipolar plate is welded with the electrode mesh, and a circular pressure plate then rolls off the assembly line. The entire process from feeding, flipping, blanking to welding is fully automated by robotic equipment. The manufacturing process is not only efficient, but also standardized, which can avoid damages to the bipolar plate coating during handling and rotation, greatly improving product quality.

 

②Spot Welding of Round Tablets

Spot welding is used for the fixation of round tablets. Compared with the traditional gluing technology, the spot welding is superior in the following aspects. First, it avoids the detachment. It has been verified by experiments that the adhesive of the round tablet would be melted and peeled off by the alkali solution during the operation of the electrolyzer, which then remains in the pressure pipe, posing a great impact on the performance. Second, it enables the firm fixation, reducing the risk of misalignment and falling during the assembly process. Third, it improves efficiency. The traditional gluing technology requires 15 minutes for drying, which affects the overall efficiency of assembly. No waiting time is required for the spot welding technology.

 

Put into use in August 2022, this A6-2525 automated PPS separator cutter has an effective operation area of 2500 mm×2500 mm. Equipped with infrared positioning and high precision linear guide rails and pinions, it can achieve an cutting accuracy of ± 0.5 mm. It is also equipped with a 12.5 KW fan that ensures the flattening of the separator through vacuum adsorption to provide consistent cutting. The automatic feeding device made up of the feeding bearing, cylinder and belt ensures the flattened separator conveys to the cutting station automatically, enabling unmanned feeding and cutting.

 

 

③PPS Separator CNC Cutter

Put into use in August 2022, this A6-2525 automated PPS separator cutter has an effective operation area of 2500 mm×2500 mm. Equipped with infrared positioning and high precision linear guide rails and pinions, it can achieve an cutting accuracy of ± 0.5 mm. It is also equipped with a 12.5 KW fan that ensures the flattening of the separator through vacuum adsorption to provide consistent cutting. The automatic feeding device made up of the feeding bearing, cylinder and belt ensures the flattened separator conveys to the cutting station automatically, enabling unmanned feeding and cutting.

 

④Electrode Laser Welding Process

The automatic electrode laser welding machine was put into use in December 2022. With the dominant PLC controlling, it is compatible for 1000 to 2500 mm electrode welding. It adopts a powerful 1500W or above continuous laser welding unit, a flat platform with movable fixtures for multi-point clamping of the bipolar plate to remove the Z-axis unevenness, and the rotary table shifts less than 0.5 mm on the Z axis with no focal length deviation of the laser welding. The pressing block adopts an arc-like design to fully press the parts. Through trial programming, it can finish the welding of an entire bipolar plate all at once by automatically skipping the hollow part in the middle. Every time the welding is completed, the turntable automatically returns to the nearest starting point of welding. Laser welding with filler wire achieves the accuracy of 0.5 mm. The welding seam is even, delicate and smooth, and the surface is white and bright.

 

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