Power electronics for green hydrogen generation with focus on methods, topologies, and comparative analysis

Abstract

This research article meticulously examines advanced power electronic converters crucial for optimizing electrolyzer perfor- mance in hydrogen production systems. It conducts a thorough review of mature electrolyzer types, detailing their specifications, electric models, manufacturers, and scalability. To meet the high current and stable DC voltage demands of industrial electrolyzers, the study delves into a broad spectrum of AC-DC and DC-DC converter topologies. It explores cutting-edge solutions like 12-pulse and 20-pulse rectifiers, advanced higher multi-pulse rectifiers utilizing conventional and auto-connected transformer units, Multi-Step Auto-connected Transformers (MSAT), polygon autotransformers, and auxiliary filters and circuits such as pulse multiplication circuits and active power filters. These innovations significantly reduce harmonic distortions and enhance power quality, addressing challenges inherent in conventional 6-pulse diode bridge rectifiers. The research also focuses on the efficiency and power factor correction capabilities of Active Front End (AFE) converters and the 3L-DNPC rectifier. Additionally, it investigates various DC-DC converters, including the Continuous Input Current Non-Isolated Bidirec- tional Interleaved Buck-Boost DC-DC Converter, the Interleaved Buck Converter (IBC) with extended duty cycles, the 3-level buck-boost converter with a coupled inductor, Quadratic converters designed for fault tolerance, the three-level interleaved buck converter, among others. Converter designs like the galvanically isolated half-bridge converter with controlled reverse-blocking switches for achieving zero voltage switching (ZVS), the Push-Pull isolated DC-DC converter prioritizing current stability, and the Isolated Full-Bridge Boost Converter (IFBBC) adept at handling fluctuating power outputs from renewable sources are also explored. Moreover, the study scrutinizes a range of converter configurations such as the Two-stage ZVT boost converter with LCL-Type SRC, multiphase interleaved DC-DC stage, and three-port isolated DC/DC converter for efficient integration with multiple energy sources concurrently. Discussing feature trends in power-to-hydrogen systems, the research reviews multi-cell modular rectifiers and multi-stage rectifiers. Overall, the study underscores the critical role of advanced converter topologies in enhancing efficiency, reliability, and power quality in electrolyzer systems, thereby contributing significantly to the progression of sustainable energy technologies.

Keywords: 12-pulse rectifiers; Active front end converters; DC-DC converters; Electrolyzers; Harmonic reduction; Interleaved buck converter; Power quality; Zero voltage switching.

Fig. 1

Illuminating the percentages of production methods, revealing the pivotal roles played by various methods in shaping the hydrogen production eco-system.

Fig. 2

Illustrates holistic power-to-hydrogen system, showcasing the interconnected components—power sources, power electronics converters, electrolyzers, and hydrogen applications—that form the foundation of a versatile and sustainable energy ecosystem.

Fig. 3

Mapping the landscape of hydrogen consumption rates across Industries.

Fig. 4

Main concept of power conditioning and control in power conversion circuits for power-to-hydrogen systems.

Fig. 5

Equivalent electrical circuit model for both dynamic and static behaviors of the Alkaline electrolyzer.

Fig. 6

PEM electrolyzer electrical circuit model.

Fig. 7

Exploring power electronics converters for different energy sources in electrolyzer applications.

Fig. 8

12-Pulse diode-based rectifier with multi-phase chopper for electrolyzes applications system diagram.

Fig. 9

12-Pulse diode rectifier with pulse multiplication circuit.

Fig. 10

12-Pulse thyristor rectifier configuration.

Fig. 11

12-Pulse thyristor rectifier with source current detection based SAPF.

Fig. 12

20-Pulse asymmetric non-isolated multi-step auto-connected transformer configuration.

Fig. 13

Auto connected-transformer-based 20-pulse AC–DC converter.

Fig. 14

Three Phase two level rectifier for electrolyzer applications.

Fig. 15

Three phase natural active Point clamped converter.

Fig. 16

Three phase T-type converter configuration for electrolyzer applications.

Fig. 17

Continuous input current non-isolated bidirectional interleaved buck-boost DC-DC converter for electrolyzer applications.

Fig. 18

Interleaved buck converter with extended duty cycle configuration for electrolyzer applications.

Fig. 19

3-level buck-boost converter with a coupled inductor for electrolyzer applications.

Fig. 20

Quadratic converters for electrolyzers utilized in DC microgrids.

Fig. 21

Three-level interleaved buck converter (TLIBC) for electrolyzer applications.

Fig. 22

DC-DC Converter for electrolyzer with low ripple and high step down.

Fig. 23

Half-bridge converter for electrolyzer applications with controlled RB switches at the secondary side.

Fig. 24

Push–Pull isolated DC-DC converter for electrolyzer applications.

Fig. 25

Bidirectional full bridge converter based on push–pull configuration for electrolyzer applications.

Fig. 26

Isolated full-bridge boost converter (IFBBC) for electrolyzer applications.

Fig. 27

Two-stage ZVT boost converter with LCL-Type SRC for electrolyzer applications.

Fig. 28

Isolated DC-DC stage with a multiphase interleaved configuration for electrolyzer applications.

Fig. 29

Three-port isolated DC/DC converter for electrolyzer applications.

Fig. 30

Modular multi-cell rectifier’s circuit diagram. (a) ISOP configuration (b) IPOP configuration.

Fig. 31

Multi-stage serial rectifier configuration.