Electrolysis DC Power Supplies: What to Know
April 13, 2023 | Topics: Fuel Cell, Power Supplies, Sustainable Energy
Electrolysis is a term that describes the process of an electric current passing through a substance to facilitate a chemical change.
Electrolysis — most commonly hydrogen electrolysis — is used for various industrial purposes, including metal plating, rust removal, water purification, chemical synthesis, and hydrogen production. The process uses a precise electric current to cause a non-spontaneous chemical reaction.
A reliable and consistent DC electrolysis power supply is required to achieve this. The power source must produce consistent amperage and a constant current.
This guide will explore the importance of the DC power supply in electrolysis, including its key features and how to choose the right option for your project.
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The process of hydrogen electrolysis
Hydrogen electrolysis is a method of producing hydrogen gas that requires water and electric energy. The process involves passing an electric current through water, H20, which causes the water molecules to break apart into hydrogen ions, H+, and oxygen ions, O-. Hydrogen electrolysis is performed in an electrolyzer containing a membrane permeable to hydrogen ions. The hydrogen ions are attracted to the negatively charged electrode (the cathode) and pass through the membrane to reach the cathode. In contrast, the oxygen ions are attracted to the positively charged electrode (the anode).
At the cathode, the hydrogen ions gain electrons from the power system and become hydrogen gas, H2. At the anode, the oxygen ions lose electrons to the electric current and become oxygen gas, O2. The two gases are collected separately. Figure 1 illustrates the electrolysis process.
Figure 1. The electrolysis process for hydrogen generation. The outputs are hydrogen and oxygen.
The electrolysis process is energy-intensive, as it requires a significant amount of electric energy to split water molecules into hydrogen and oxygen. Producing 1 kg of hydrogen, using solar power as the energy source for a power system requires at least 50 kWh. A facility producing 100 kg of H2/day needs at least a 230 kW power system.
Understanding Electrolysis Power Supplies
An electrolysis power supply is a special device designed to provide the precise DC voltage and current necessary for electrolysis. Unlike standard power supplies, which are used as a battery charger, these units are tailored to meet the unique demands of electrolysis, ensuring stable and reliable power delivery.
Consistency in DC output is crucial, as fluctuations can lead to inefficiencies or even damage the electrolytic cell and other equipment involved in the process, such as the anode, electrolysis tank, rectifier, and diodes.
Due to the precise voltage regulation demands, it’s vital that you use a high-quality converter for your project. While you can perform electrolysis with DIY car battery chargers or cheaper solutions from Amazon or eBay, the risk of an accident or damage to your equipment is high.
Elektro Automatik (EA) Powered provides more robust electrolysis power supply options that offer exceptional precision and control over your output. Our bidirectional DC power supply features a stainless steel shell, regenerative capabilities to reduce electrical waste, and an ultra-efficient design.
We also offer an autoranging DC power supply that automatically maintains the ideal current output while keeping all other variables, including volts and amperage, within set ranges.
You can use our autoranging equipment as an electrolysis power supply. It’s also great for other types of projects due to its ability to produce a wide range of outputs.
Key Features of an Electrolysis Power Supply
An electrolysis power supply and a basic DC converter aren’t one and the same. The latter functions as little more than a manual battery charger. By contrast, our high-end electrolysis power supply solutions are filled with useful features and tools designed to support your project and maximize your return on investment.
Here are a few of the features you need in an electrolysis power supply.
Voltage and Current Control
One of the most important features of an electrolysis power supply is its ability to precisely control voltage and current. You must keep your solution or cell within a specific range to prompt a chemical reaction. Different applications require different voltage and current levels, meaning your output needs will vary from one project to the next.
For instance, water electrolysis for hydrogen production might need different settings than electrolysis for metal plating. A power supply with adjustable outputs allows you to fine-tune parameters for each application, ensuring efficient, frustration-free electrolysis.
The need for complete control over voltage and current outputs is also one of the strongest cases against a DIY power supply.
Cheap options simply don’t provide the level of control necessary to keep current and voltage within the proper ranges. These inconsistencies could lead to a variety of challenges, including inefficient hydrogen production or poor plating adherence, depending on the nature of your project.
Stability and Reliability
Stability and reliability are paramount when it comes to electrolysis power supplies. Once you’ve triggered a chemical reaction, you need to keep the subject material within that range to continue the process. Any fluctuations or interruptions in power delivery can disrupt the process, leading to subpar results or even equipment damage.
High-quality power supplies are designed to provide consistent output. Maintaining the set voltage and current levels throughout your project will ensure that the electrochemical reactions proceed as you intend.
Keeping your power supply stable throughout the project also promotes better worker and site safety. Applying too much current and voltage to a subject material could create potentially dangerous conditions.
Safety Features
A high-quality electrolysis power supply will include numerous safety features designed to protect both the equipment and the operator. These may include overcurrent protection, short-circuit protection, and thermal shutdown. Such features help prevent accidents and equipment damage, ensuring a safe and reliable electrolysis process.
Keeping your team safe can help prevent workplace accidents and subsequent worker’s comp claims. Investing in safe machinery may also improve compliance and protect your business from the reputational damage that occurs following a negligence-related accident.
Choosing the Right DC Power Supply for Electrolysis
Finding the ideal electrolysis power supply requires you to identify your specific project requirements and intended use case.
Don’t rely on broad statements like, “We need to facilitate hydrogen electrolysis.” Instead, work with your team to identify your unique needs. Make a list of your voltage and current requirements, must-have features, and maintenance concerns.
It’s also wise to look beyond your current project and consider how you’ll use the power supply in the future. Investing in a versatile machine may cost more up front, but it will deliver a long-term return on investment by supporting various projects and tasks.
Here are three of the main variables you should consider when selecting your electrolysis power supply.
Voltage and Current Requirements
Understanding the specific voltage and current needs of your application will help you eliminate equipment that doesn’t meet your minimum requirements.
Different processes require various power settings. For example, water electrolysis typically requires a higher voltage but lower current compared to metal plating. Knowing the exact requirements of your project will help you select a power supply that can meet those needs without underperforming or overloading your equipment.
The voltage and current output capabilities should be the first feature you consider. If a piece of equipment can’t produce enough power to complete your project, there’s no use in reviewing its efficiency, maintenance requirements, or durability — simply cross it off your list of prospective solutions and continue your search.
Power Supply Efficiency
Efficiency is another central factor to consider when choosing an electrolysis power supply. Higher efficiency means less energy wasted as heat. An efficient bidirectional option will drastically reduce your operating costs and improve overall performance.
Look for power supplies with high-efficiency ratings to make sure your process is both cost-effective and environmentally friendly. Paying a little more up front can lead to long-term cost savings while providing better project performance.
Durability and Maintenance
Electrolysis can be demanding on your equipment. Choose a durable power supply that can hold up to the rigors of electrolysis and other high-output processes. Remember that your machine will be exposed to chemicals and high temperatures. A stainless steel option may be better suited for these types of projects, as it won’t rust or corrode.
Also, consider the maintenance requirements of the power supply you choose. Opt for models that are easy to maintain and have a reputation for long-term reliability to ensure continuous, trouble-free operation.
Practical Tips for Using a DC Power Supply for Electrolysis
Choosing the right equipment is a critical first step. However, you need to master the art of using your power supply to get the most out of your investment. Here are three areas of concern you should consider when using a DC power supply for electrolysis.
Proper Setup and Configuration
Take the time to familiarize yourself with your equipment by reading the manual and watching various tutorials. Make sure the machine is properly connected to the electrolytic cell and that all connections are secure.
Adjust the voltage and current settings according to the requirements of your specific electrolysis process. Double-check all parameters before getting started to avoid any potential issues.
While you’ll undoubtedly be eager to jump into your first test, resist the urge. Get to know your equipment, including its controls and features, before running any experiments.
Taking a few hours to review the user manual, get acquainted with the controls, and adjust the settings will go a long way in promoting safety and efficiency. Besides, you don’t want to accidentally damage your brand-new machine by misusing it on the first day.
Safety
Always wear appropriate personal protective equipment (PPE), such as gloves and safety goggles. Additionally, double-check that your supply is equipped with the latest safety features and that you know how to use them.
Regularly inspect the machine for any signs of wear or damage. Address any issues promptly, and never use the equipment if it’s been damaged.
Maintenance
Follow all maintenance instructions as outlined in the user manual. Keep the power supply clean and free from dust and debris. Periodically check all connections and components to confirm that they’re in good working condition.
Stick to the maintenance schedule and avoid skipping inspections or key upkeep tasks. Doing so could compromise your warranty and create safety issues.
Applications of Electrolysis Power Supplies
You can use your electrolysis power supply for any of the following projects:
Metal Plating
Electrolysis can be used to deposit a thin layer of metal onto a surface. This process requires precise control of voltage and current to achieve a uniform, high-quality finish. Electrolysis power supplies provide the necessary control and stability to ensure that your plating process goes smoothly.
Water Splitting
Electrolysis of water produces hydrogen and oxygen gas. This process requires a higher voltage but lower current compared to other forms of electrolysis.
Chemical Synthesis
You can also use electrolysis to trigger various chemical synthesis reactions and produce compounds such as chlorine, sodium hydroxide, etc. These processes also require acute control of voltage and current to achieve the desired outcomes.
Scalable and dependable power for reliable electrolysis
Let’s look at possible solutions for the intense energy requirements for hydrogen production. A modular EA Elektro-Automatik power rack can provide the power necessary for any size hydrogen electrolysis plant. A rack, like the one shown in Figure 2, can provide up to 300 kW of power with up to five EA-PU 10000 6U, 60 kW power supplies. The high density, 6U, 60 kW power supplies allow production floor space savings since only one rack is needed to deliver as much as 300 kW.
An additional 12 racks can combine to generate up to 3.84 MW of total output power. One power supply acts as the controller for up to 63 more power supplies in a master-auxiliary configuration to create a system as large as 64 paralleled power supplies. To ensure a system operates safely, a Share-Bus™ link between all the supplies ensures that each supply shares a portion of the load equally. The Share-Bus link balances the energy delivered to the load evenly among all the power supplies.
As well as protecting a system of paralleled power supplies, the Share-Bus control link can de-energize the output of a defective power supply. Once the defective power supply is removed from the system, the power rack can be re-initialized and continue to output power for the hydrolysis process following a minimum amount of system downtime. Thus, an EA power rack offers extensive scalability to generate up 3.84 MW of fail-safe power.
Figure 2. One EA power rack, with 8 power supplies can provide up to 240 kW with substantial production floor space savings.
Wide-ranging output for maximum DC power supply performance
EA programmable DC power supplies have a true autoranging output characteristic (see Figure 3), providing a much wider voltage and current output than a comparable capacity power supply with a conventional rectangular output characteristic. Unlike a rectangular output characteristic power supply that can only deliver full power at one point, the maximum voltage and maximum current point, the EA true autoranging power supplies deliver full power from the maximum rated voltage all the way down to 1/3 of the maximum rated voltage, without the need to stop and switch. The wide voltage and current outputs of an EA autoranging power supply can potentially reduce the size and number of power supplies needed for a system, offering significant cost savings.
Figure 3. Output characteristic of a 30 kW true autoranging EA power supply with a 500 V maximum voltage rating. Note how the power supply can deliver full power from 500 V down to 166.6 V.Easily controlled with a PC or a programmable logic controller (PLC)
Now, let’s look at options in monitoring and the choice of interface for automated control of a system. An EA power supply can interface with the USB interface or the Ethernet interface on a PC. Optional interfaces include, among other optional interfaces, a CAN bus interface and a Profibus interface for control from a PLC. Furthermore, EA DC power supplies have a SCPI command operating mode to allow control from PC programs and a Modbus command operating mode for PLC control.
With the Ethernet interface, engineers can provide diagnostic and maintenance support from a remote location to minimize system downtime. Thus a hydrogen electrolysis facility can ensure a cost-effective life cycle for the power rack.
Fully assembled for safety and fast installation
Systems are pre-wired and comply with international safety standards. Power racks, such as shown in Figure 4, are professionally wired and completely documented. Furthermore, EA ships all power racks fully tested to published specifications. All that is required for installation is AC power and system cooling. EA power racks can be air- or water-cooled depending on facility requirements.
Figure 4. The rear of an EA power rack showing highly ordered and secured wiring and the bus bar-assembled parallel output down the center of the rack.Future-proofing your line with DC programmable power supplies that grow with your production needs
Every aspect of renewable energy seems to be improving year after year, and fuel cell efficiency is no exception. As efficiency continues to grow, the demand will also increase as industries can no longer ignore a viable source of formidable power. Procuring the highest power density supplies will meet your programmable power needs now and higher power production in the future without having to redo your line.
Source Your DC Power Supply for Electrolysis From EA Powered
An electrolysis power supply is a versatile piece of equipment that can make a great addition to your lab. However, it’s imperative that you choose a high-quality machine from a reputable provider.
Elektro Automatik (EA) Powered provides a wide range of tools designed to support your experience and design projects. Our DC power supply for electrolysis is one of our most popular offerings. This powerful solution can support a multitude of use cases by delivering precise output voltage.
