Optimizing electrolyser cooling processes

A significant part of the future hydrogen demand is estimated to be produced in electrolysers (alkaline/PEM/solid oxide). Maximizing the efficiency and lifetime of these hydrogen electrolysers will be crucial for decarbonization. In today’s technologies, 20-40% of the hydrogen electrolyser capacity is turned into excess heat that needs to be continuously cooled off.

No matter if it’s the commercial electrolyser technologies on the market today, or the ongoing development of the next generation of electrolyser, optimizing the electrolysers cooling as well as the hydrogen plant itself is a key success factor for efficient and scalable green hydrogen production.

Energy efficient green hydrogen production

When renewable electricity is splitting water molecules into hydrogen and oxygen in an alkaline/PEM electrolyser, a large part of the electrolyser capacity is turned into excess heat. By cooling off the heat in an efficient, compact and scalable way – we not only maximize the efficiency and lifetime of the hydrogen electrolyser itself, it also allows for further repurposing of this excess heat.

By not letting excess energy go to waste, the overall efficiency of green hydrogen production can increase.

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Hydrogen plants: We understand reducing OpEx and CapEx is mandatory to ensure a cost competitive green hydrogen production. With Alfa Laval’s heat transfer technology, we enable a lower levelised cost of hydrogen.

• Reducing costs
• Enabling heat recovery
• Productivity first

Heat exchanger tech: The new generation of Alfa Laval semi-welded plate heat exchangers takes pressure weighting to the next level, designed for optimised performance to guarantee a reliable operation in the electrolyser system.

• Handles high pressure
• Flexible configuration
• Space saving

Service solutions: Equipment used in hydrogen production must be handled in a very careful manner. Connected services ensure safety by monitoring the health status of the plate heat exchanger as well as prolonging the lifetime of the equipment.

• Ensure safety
• Accelerate sustainability
• Efficient for decades

Efficient cooling electrolyser system with Alfa Laval heat exchangers

The electrolyser stack⁽¹⁾ is the core of the process, where the electricity is concentrated and the water is electrolysed into this most simple elements—hydrogen and oxygen. To maintain efficiency and extend equipment lifespan, temperature control is essential. This is where the anolyte coolers ⁽²⁾and catholyte coolers ⁽³⁾come in, ensuring the stack remains at optimal temperature by removing waste heat generated during electrolysis. Alfa Laval heat exchangers are perfectly suited for this task, not only maintaining system stability but also enabling heat recovery for added efficiency.

Beyond the electrolyte cooling, hydrogen gas coolers ⁽⁴⁾and oxygen gas coolers⁽⁵⁾ play a crucial role in green hydrogen production. By reducing gas temperatures to the lowest possible levels, they help optimise overall efficiency. Alfa Laval’s robust heat exchangers ensure safe operation while also offering the opportunity to recover heat from the gases, making the process even more energy efficient.

Electrolyser stack

1. Electrolyser stack

Electrolyte coolers

2. Anolyte cooler

3. Catholyte cooler

Gas coolers

4. Hydrogen gas cooler

5. Oxygen gas cooler

"Зелений" водень дає надію на майбутнє

Використання "зеленого" водню вже давно розглядається як передумова досягнення європейських кліматичних цілей. Зараз у Німеччині новий пілотний проект демонструє потенціал для втілення цього в життя. Використовуючи теплообмінники Альфа Лаваль, компанія Thyssenkrupp Uhde Chlorine Engineers GmbH тестує водень замість вугілля, щоб зменшити викиди CO₂ при експлуатації доменних печей на виробництві в м.Дуйсбург.

Цей проект, який фінансується німецьким урядом, використовує металургійні гази, які утворюютиься під час виробництва сталі, для виробництва хімічних речовин, тим самим зменшуючи викиди CO₂. Перегляньте повну історію, щоб дізнатися про вирішальну роль, яку відіграла технологія Альфа Лаваль у цьому пілотному проекті

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Supplies the world’s largest green hydrogen plant

Alfa Laval has signed an agreement to deliver compact heat exchangers to the world’s largest green hydrogen plant, which is to be constructed in the Middle East. The facility, powered by renewable energy, will be part of the city of Neom, built from scratch in the northwestern desert, with the ambition of establishing a new model for sustainable living.

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Alfa Laval’s offering in green hydrogen production

• Highly efficient and flexible
• Space-saving compact unit
• Low operating cost possible owing to superior energy efficiency and prolonged service intervals
• Safe and reliable sealing with no risk of cross-contamination
• Pressure and temperature fatigue resistant

Meet with modern requirements

• Highest thermal efficiency and close temperature approach
• Compact units - space saving, easy to service and maintain
• Maximum uptime - less fouling, stress, wear and corrosion
• Flexible - easy to adapt to changed duty requirements

Sustainable, safe and cost-efficient

• Alfa Laval’s patented AlfaFusion technology
• 100% stainless steel construction
• Virtually maintenance free
• Reduced installation costs

For all Alfa Laval heat exchangers

• Automatic backflushing for uninterrupted filtering process
• Easy installation and maintenance
• Increased cooling system uptime and lower maintenance costs
• Proven, reliable technology