Solar Hydrogen
Solar Hydrogen
Solar Hydrogen
H
ydrogen gas (H2)
can be used for
cooking, water
heating, space heating,
electricity generation,
welding and cutting, and
the synthesis and
purification of other
chemical materials. When
hydrogen is made from
water and renewable
energy resources such as
PV, wind, or microhydro,
we refer to the produced
gas as “solar-hydrogen.”
Above: Electrolyzers driven by photovoltaics.
Solar-hydrogen is a sustainable carbon-free gas. It can we are located on a hillside in an urban area, a wind
release heat when burned with air or oxygen, or generator tower would not be a welcome addition to our
produce electricity when combined electrochemically neighbors’ view. With this in mind, we use PV electricity
with oxygen in a fuel cell. When solar-hydrogen is made as the exclusive renewable power source for our
or burned, there is no carbon monoxide, carbon dioxide hydrogen plant.
“greenhouse gas,” or hydrocarbon pollutants produced.
Solec 50 peak-Watt PVs (A, see diagrams on pages 43
This article discusses hydrogen purification as a and 45) are arranged in eight panel arrays. They are
prerequisite to storage or utilization, and covers safety wired in series-parallel for 24 Volts. Three of these
considerations in home power applications. arrays, totaling 24 panels, will produce sufficient power
to run our Hydrogen Wind twelve-cell electrolyzer at
Where Does Hydrogen Gas Come From? nearly its rated 1 kW capacity.
1. RE Electrolysis of H2 Gas
Our Hydrogen Wind electrolyzer (B) is shown in the
We use PV electricity to run an alkaline electrolyzer to
diagrams with its associated purifiers and storage
produce hydrogen gas. Unfortunately, we do not have a
tanks. For more information on the production of
creek or other water resource nearby for micro-hydro
hydrogen by electrolysis and hydrogen storage, see
electricity production. We could really use it during the
HP39 and HP59, respectively.
rainy season when there is less solar insolation. Since
Power Electrolyzer
PV
B C I Vent
Water 1st
Electrolyzer F Valve
Drain Flash-back
Valve Arrestor
Bidirectional
Double-Bubbler Fill / Drain Hydrogen Storage Tank
DC Power Source Valve
(Twenty-four Solec
50 Watt PV modules Recombination
wired for 24 Volts) Catalyst D
temperature or higher, and results in the formation of
water vapor, which is easily removed if necessary. Pressure / Vacuum Gauge
Desiccant dryers absorb water vapor from the gas by Safety Levels of Oxygen Contamination
contact with a chemical substance like calcium chloride. 7
One popular lab gas desiccant is called Drierite. It 6.1
includes a color indicator to show when the desiccant 6
must be regenerated. The color turns from blue to pink
% Oxygen Contaminent
when water is absorbed. The desiccant is dried by 5
in Hydrogen Produced
heating or evacuation for recycle. Dangerous
4
Not Safe
Safe H2 Storage 3.0 Safe to Use
2.8
You are responsible for the purity of the solar-hydrogen 3
to be stored. Hydrogen and oxygen mixtures are not
Low PV output
safe to store. Make sure that your gas is at least 99% 2
D.O.T. max O2 in H2
Industrial H2
Research Grade H2
Electrolyzer H2
Electrolyzer H2
(after purifyer)
Upper Flammable
Limit
Oxygen is the impurity of concern, so measure for it in
your hydrogen on a regular basis. The strategy for safe
hydrogen storage includes using 99+% pure gas, and
eliminating the oxygen impurity.
Homebrew Purification System
A hydrogen purifier was constructed for our 1 kW home- filter media in the coalescers. It is compatible with
scale alkaline-electrolysis hydrogen production plant. hydrogen gas and can be used on the oxygen side as
We chose a catalytic recombination process to remove well.
the oxygen impurity. Details are shown.
These coalescers are position-dependent, and must be
A Double-Bubbler (C) with water columns and sparger- mounted so that their water capturing bowls and drain
frit aquarium-type bubblers can provide several useful valves face down. The coalescers require horizontal
functions. It can serve as a visual flow indicator, KOH piping connections at the entrance and exit. With
scrubber, flame arrestor, liquid back-flow preventer (for horizontal piping, the bowls will gravity fill with
intermittent operation), upstream or downstream leak coalesced water.
detector, and imbalance detector (requires 2 units for
Each coalescer is equipped with a small ball valve on
comparison of O2 and H2 production).
the bottom of the bowl to allow regular draining of water
The water in the bubbler columns must be changed captured from the hydrogen. The coalescers must NOT
during regular maintenance servicing, as it becomes be allowed to fill up with water. We drain the water from
alkaline over time. Some operators have reported using the coalescers about once a week.
cider vinegar instead of water for longer life between
Flash-back Arrestors
column liquid changes. A color change apparently
Flash-back arrestors (FBA) (F) are used to isolate the
occurs when the acidity of the vinegar is neutralized by
purifier from other components upstream or
the KOH/water aerosols. Soon, we’re going to try it here
downstream in the hydrogen system piping. An FBA will
to see for ourselves.
stop a flame from propagating through a pipe.
Water Coalescers and Water Drain Valves
Hydrogen is flammable and easily ignited when oxygen
Our coalescers (E) have stainless steel bodies, and
is present. The FBA isolates flammable air and
bowls with replaceable filter elements inside. The
hydrogen, or oxygen and hydrogen mixtures, from any
coalescer filter removes rust, nickel, plastic, and dirt
source of ignition. An open flame, spark, or hot metal
particles from the hydrogen gas stream. Coalescers
surface can be a source of ignition.
also remove water vapor aerosols, known as fog.
A catalyst can also be a source of ignition, even at room
The first coalescer removes bubbler aerosol. The
temperature. By bracketing the catalyst with an FBA on
second removes recombination-water aerosol,
either side, the upstream or downstream mixture will
produced by deoxidation of the hydrogen as it passes
not be ignited. This is true even if there is a flammable
over the catalyst beads. Our coalescer is a Finite unit
mixture in the line due to a malfunction or mistake.
manufactured by Parker Hannifin Corp. It captures
water aerosols in the 0.001 to 10 micron size, using a FBAs are made with a plug of fine silica sand restrained
glass micro-fiber element. We chose to use a type C by screens in a wide section of piping. The sand
Left: The through the top and exits at the bottom. This will
Panametrics prevent lofting the particles in the catalyst bed and
XMO2 oxygen fluidizing them. Keeping the catalyst pipe vertically
analyzer oriented helps to keep the flow uniform. Thus, the water
measures the formed during de-oxo purification flows towards the
amount of O2 bottom in the same direction as the hydrogen gas. It
contaminant in can be removed from the purified hydrogen by the
the hydrogen. second coalescer before it reaches the second FBA.
Connecting the Purifier to the Electrolyzer
The hydrogen duct coming from the electrolyzer is first
connected to the gas inlet port of the Double-Bubbler
for KOH/water scrubbing. The scrubbed hydrogen gas
is then fed to the purifier for oxygen removal. We used
1/4 inch stainless tubing with Swagelok fittings to
connect the electrolyzer, bubbler, and purifier.
Purging the Purifier
Before starting the hydrogen plant, flush any possible
flammable gas mixture out of the piping with an inert
purge gas, like nitrogen or carbon dioxide.
An alternate method to remove flammable gas mixtures
from the piping and other components is to use a
mechanical vacuum pump (I). It must be capable of
producing a vacuum of at least 20 mbar (approximately
quenches any flame-front and stops combustion. We 20 Torr). A vacuum cleaner will not work for this. A two-
prefer the FBAs that have an integral check valve to stage laboratory vane-type vacuum pump with a
prevent backflow. Western Enterprises, Inc. makes an thermocouple pressure gauge will work well.
FBA appropriate for hydrogen and acetylene gas
Compound pressure gauges are very useful, because
service.
you can see when the vacuum has reached less than
Check Valve Pressure Relief 20 millibar (>29 inches Hg vacuum). It is also easy to
A check valve (G) for pressure relief is set to 4 bar (58 check if the piping holds vacuum after the pump is
psig) to prevent over-pressuring the system by error. If removed. Vacuum measurement units have become
this pressure is exceeded, the relief check valve more standardized in recent years. Unfortunately, many
“cracks” and hydrogen gas is released out of the vent gauges are still on the market that register vacuum in
line. When the pressure is reduced to the normal inches or millimeters of Hg (mercury) below
operating value (0.5 to 3.5 bar gauge), the valve closes atmospheric pressure. This can be confusing to the
once again. Relief valves are subject to drift over time, uninitiated.
so check to be sure that the set pressure and the actual
Startup of Electrolyzer and Purifier
pressure are the same. This should be done at regular
Once the purifier is ready, we start the electrolyzer by
maintenance shutdowns.
closing the main electrical breaker to the DC power
Compound Pressure Gauges supply. Then, we wait twenty minutes or so for the float
We use pressure gauges (H) with all stainless parts to valves on the Hydrogen Wind electrolyzer to fill. Next,
prevent corrosion failure. They are compound gauges we close the vent valve on the electrolyzer. Pressure in
measuring both vacuum and pressure. We use the the electrolyzer will begin to rise. Slowly, we open the
vacuum gauge function to evacuate the system after isolation valve between the electrolyzer and the
maintenance, or before startup of the hydrogen plant. Double-Bubbler. Gas will enter the purged purifier. After
The pressure gauge monitors operation of the plant the hydrogen flow through the Double-Bubbler has
when making hydrogen gas. stabilized, we open the isolation valve all the way, and
leave the valve open.
De-oxo Catalytic Recombiner
Our catalyst (D) is packed in a stainless steel tube by Measuring Hydrogen Purity
the supplier and performs the key purification function: When production of gas is underway, we check the
removing oxygen from the hydrogen gas stream. The purity of the gas before storage. Several oxygen meters
catalyst tube must be placed so that the flow enters are available. We use a Panametrics XMO2 oxygen