WO2025038437A2 - Optimisation de convertisseur de puissance - Google Patents

Optimisation de convertisseur de puissance Download PDF

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Publication number
WO2025038437A2
WO2025038437A2 PCT/US2024/041685 US2024041685W WO2025038437A2 WO 2025038437 A2 WO2025038437 A2 WO 2025038437A2 US 2024041685 W US2024041685 W US 2024041685W WO 2025038437 A2 WO2025038437 A2 WO 2025038437A2
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WO
WIPO (PCT)
Prior art keywords
load
voltage
power converter
turn
current
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/041685
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English (en)
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WO2025038437A3 (fr
Inventor
Yang Liu
Raffi Garabedian
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Electric Hydrogen Co
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Electric Hydrogen Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Publication of WO2025038437A2 publication Critical patent/WO2025038437A2/fr
Publication of WO2025038437A3 publication Critical patent/WO2025038437A3/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/007—Plural converter units in cascade
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B15/00—Operating or servicing cells
    • C25B15/02—Process control or regulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of DC power input into DC power output
    • H02M3/02—Conversion of DC power input into DC power output without intermediate conversion into AC
    • H02M3/04—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters
    • H02M3/10—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/02—Conversion of AC power input into DC power output without possibility of reversal
    • H02M7/04—Conversion of AC power input into DC power output without possibility of reversal by static converters
    • H02M7/06—Conversion of AC power input into DC power output without possibility of reversal by static converters using discharge tubes without control electrode or semiconductor devices without control electrode
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/02—Conversion of AC power input into DC power output without possibility of reversal
    • H02M7/04—Conversion of AC power input into DC power output without possibility of reversal by static converters
    • H02M7/06—Conversion of AC power input into DC power output without possibility of reversal by static converters using discharge tubes without control electrode or semiconductor devices without control electrode
    • H02M7/08—Conversion of AC power input into DC power output without possibility of reversal by static converters using discharge tubes without control electrode or semiconductor devices without control electrode arranged for operation in parallel

Definitions

  • the disclosure relates generally to optimization of a power converter for an electrochemical stack. b. Brief Description of Related Technology
  • Electrolyzer systems use electrical energy to drive a chemical reaction. For example, water is split to form hydrogen and oxygen. The products may be used as energy sources for later use.
  • improvements in operational efficiency have made electrolyzer systems competitive market solutions for energy storage, generation, and/or transport. For example, the cost of generation may be below $10 per kilogram of hydrogen in some cases. Increases in efficiency and/or improvements in operation will continue to drive installation of electrolyzer systems.
  • Fig. 1 is a block diagram of an example power supply system 100, according to various implementations.
  • FIG. 2 is a flow chart showing example power supply logic (PSL), according to various implementations.
  • PSL power supply logic
  • Fig. 3 shows an example power supply system for an electrolysis system, according to various implementations.
  • Fig. 4 shows another example power supply system for an electrolysis system, according to various implementations.
  • the discussed architectures and techniques may support large-scale (and/or other scale) electrolysis systems directly or virtually connected to a renewable generation energy source, and/or electrolysis systems providing grid services. Everything described here can also be applied to electrochemical processes other than electrolysis, for example electrochemical reduction of oxide ores, chloralkali processes and the like, so long as they are powered directly by resources utilizing controllable power converter.
  • the discussed architectures and techniques disclosed herein may also be configured to operate electrochemical cells within an electrochemical stack with 200 mV or less of pure resistive loss when operating at a high current density (e.g., at least 3 Amps/cm 2 , at least 4 Amps/cm 2 , at least 5 Amps/cm 2 , at least 6 Amps/cm 2 , at least 7 Amps/cm 2 , at least 8 Amps/cm 2 , at least 9 Amps/cm 2 , or at least 10 Amps/cm 2 ).
  • a high current density e.g., at least 3 Amps/cm 2 , at least 4 Amps/cm 2 , at least 5 Amps/cm 2 , at least 6 Amps/cm 2 , at least 7 Amps/cm 2 , at least 8 Amps/cm 2 , at least 9 Amps/cm 2 , or at least 10 Amps/cm 2
  • the discussed architectures and techniques disclosed herein may be applied in the formation or operation of a large-scale electrochemical plant that may be configured to generate at least 1 megawatt (MW) of power, at least 5 MW, at least 10 MW, at least 25 MW, at least 50 MW, at least 75 MW, at least 100 MW, in a range of 1-100 MW, in a range of 10-100 MW, in a range of 25-100 MW, or in a range of 50-100 MW of power.
  • MW megawatt
  • Power converters that supply power to high power electrochemical stacks may be based on boost topologies. These power converters have intrinsic limits in output voltage control range based on their finite input current ratings. As boost converters, their minimum output voltage is proportional to their input voltage, and the lower the input voltage, the higher the input current for a given converter output current rating. These constraints may result in high power converter costs.
  • Typical boost power converters for electrochemical stacks are controlled from 0% to 100% of full current required for the electrochemical stack.
  • a typical boost converter is configured to have a boost ratio that steps up an input voltage to an output voltage in the range from a turn-on voltage corresponding to zero, or almost zero, current to a maximum voltage corresponding to 100% of full current required for the electrochemical stack. Due to the wide control range and high boost ratio of the traditional boost power converter, the power converter suffers from efficiency loss, particularly towards the higher end of the control range of the power converter.
  • control range that is used during operation of the electrolyzer stack typically does not start at zero current.
  • the lower 10% of the control range may be not used during operation of the electrolyzer stack.
  • the lower end of the control range of the power converter may not necessarily be needed during operation. Nonetheless, the power converter may be designed to safely traverse this lower range to achieve stable control at the higher range. For example, a range that starts at a voltage that is 10% above the turn-on voltage of the electrolyzer may be used.
  • Embodiments described herein provide a power supply system for an electrolyzer stack configured to pre-charge the electrolyzer stack to a voltage that is above a turn-on voltage that corresponds to zero, and/or nearly zero, current drawn by the electrolyzer stack, prior to turning on a power converter (e.g., rectifier) to provide power to the electrolyzer stack.
  • the power supply system may be configured to pre-charge the electrolyzer stack to a voltage that corresponds to a certain percentage (e.g., 10%, 15%, etc.) of full current for the electrolyzer stack.
  • Pre-charging may be performed by a switched inrush current limiter configured to allow the electrolyzer stack to traverse the voltage range up to the certain percentage (e.g., up to 10% above the turn-on voltage, up to 15% above the turn-on voltage, and/or other proportional value) before the power converter is turned on.
  • a switched inrush current limiter configured to allow the electrolyzer stack to traverse the voltage range up to the certain percentage (e.g., up to 10% above the turn-on voltage, up to 15% above the turn-on voltage, and/or other proportional value) before the power converter is turned on.
  • embodiments of the power supply system allow for a smaller power converter and/or fewer power converter blocks for a given electrolyzer stack as compared, for example, to power supply systems that pre-charge the electrolyzer stack to the turn-on voltage and control a power converter in the range from the turn-on voltage to 100% voltage of the electrolyzer stack.
  • Fig. 1 shows a block diagram of an example power supply system 100, according to various implementations.
  • the power supply system 100 includes an input port for coupling the power supply system to a power source, such as the grid or a renewable energy (e.g., solar, wind, and/or other renewable source) power source and an output port for coupling the power supply system to a load 110.
  • the load 110 may be an electrochemical (e.g., electrolyzer) stack, for example.
  • the power system 100 also includes a power converter 112 and a pre-charge system 114.
  • the power converter 112 may include a rectifier configured to convert AC power of the power source to DC power and a boost converter configured to step-up the power to generated required DC power at the output port.
  • the pre-charge system 1 14 may include circuitry configured to operate at start-up of the load 110 to pre-charge the load 110 to a volage that is higher than a turn-on voltage of the load.
  • the pre-charge system 114 is configured to pre-charge the load to a voltage that corresponds to a certain percentage (e.g., 10%, 15%, etc.) of maximum current used by the load.
  • a certain percentage e.g. 10%, 15%, etc.
  • the power supply system 100 turns on the power converter 112 and switch the output port from the pre-charge system 114 to the power converter 112.
  • the power converter 112 is turned on passed the turn-on of the load 110 and during an operating mode of the load 110. Therefrom, the remainder of the voltage/current range of the load may be provided by the power converter 112.
  • the power converter 112 may have a reduced control range as compared to systems in which a power converter covers the entire voltage/current range of the load.
  • the power converter 112 may have a control range that only covers 10% to 100% of the voltage/current range required by the load. Due to the reduced control range of the power converter 112, efficiency of the power converter 112 may be improved, in at least some embodiments.
  • the power converter 112 may be smaller (e.g., include smaller components, include fewer power converter blocks, etc.) and cheaper as compared to systems in which power converters configured to cover the entire voltage/current range of the load, in at least some embodiments.
  • the pre-charge system 1 14 includes a switched inrush current limiter configured to allow the load to traverse the voltage range up to the certain percentage (e.g., up to 10% above the turn-on voltage, up to 15% above the turn-on voltage, etc.) before the power converter 112 is turned on. Because the pre-charge system 114 is configured to pre-charge the load beyond the start-up voltage of the load, the inrush current limiter is designed to handle a certain amount of current, such as current up to 10% or 15% of the full current required by the load 110.
  • the inrush current limiter is designed to handle a certain amount of current, such as current up to 10% or 15% of the full current required by the load 110.
  • the pre-charge system 114 includes a switched pre-charge element provided between the output of the power converter 112 and the load 110.
  • the power supply system 100 may first pre-charge a capacitor at the output of the power converter 112 to the voltage that is higher than the turn-on voltage of the load.
  • the pre-charge element may then be used to pre-charge the load to be approximately equal to the pre-charged output of the power converter 112, so that the output of the power supply 100 can be safely switched from the precharge circuitry 1 14 to the power converter 1 12.
  • the switched pre-charge element may include a resistor provided between the output of the power converter 112 and the load 110. The resistor may be properly sized based on an equivalent resistance at the input of the load 110.
  • the resistor may be sized small enough so as to not cause a significant volage drop by a voltage divider created by the resistor and the equivalent resistance of the load.
  • the resistor may be sized large enough such that the resistor can handle the current up to the certain percentage of the full current required by the load 110 (e.g., up to 10% or 15% of the full current required by the load 110) without generating too much heat.
  • An example power supply system in which a switched resistor is provided to precharge a load to a voltage that is higher than a turn-on voltage of the load, according to an embodiment, is described in more detail below in connection with Fig. 3.
  • switched pre-charge element may include an inductor provided between the output of the power converter 112 and the load 110. Current flowing through the inductor may be modulated so as to distribute heat generated as the current flows through the inductor over time.
  • An example power supply system in which a switched inductor is provided to pre-charge a load to a voltage that is higher than a turn-on voltage of the load, according to an embodiment, is described in more detail below in connection with Fig. 4.
  • Fig. 2 is a flow chart showing example power supply logic (PSL) 200, which may be used with various power supply systems including the example power supply system 100, according to an embodiment.
  • the PSL 200 may be implemented on power supply circuitry.
  • the PSL 200 may pre-charge, using a pre-charge system, a load to a voltage that is above a turn-on voltage of a load (202).
  • the PSL 200 may switch output of the power supply system from the pre-charge system to an output of a power converter (204).
  • the power converter may be controlled (e.g., to provide a controlled voltage and/or current output) within a control range that begins at the voltage higher than the turn-on voltage of the load (206).
  • the power converter may thus have a control range that covers voltage/current that begins at the voltage that is higher than the turn-on voltage of the load. Accordingly, the power converter may have a reduced control range and improved efficiency as compared to a power converter configured have a control range that covers the entire voltage/current range that begins from the turn-on voltage of the load.
  • a typical electrolyzer may include multiple electrolyzer cells.
  • the typical Vmax for each cell at end of life is 2. IV at 100% current.
  • Typical Vtumon is 1.45V at nearly zero current.
  • Typical V io% is 1 .55 V at 10% current.
  • a power converter must typically be specified to control current across this entire range of 0.65V. However, the bottom 0.10V are not useful in the application, though the converter must safely traverse this range to achieve stable control at Vio%. In this scenario, 15% of the converter’s voltage range is consumed only during turn on transients, adding power system cost roughly proportionally, without adding value during operation.
  • a switched inrush current limiter is provided to allow the stack to traverse this 0-10% range up to Vio% before turning on the power converter.
  • Fig. 3 shows an illustrative example power supply system 300 for an electrolysis system, according to an embodiment.
  • a pre-charge system 314 includes a switched series resistor 316 provided between an output of a rectifier 312 and a power supply input of an electrolyzer stack 310.
  • a transformer 303 is provided to transform power from a power source, such as grid power, to a power usable by the power supply system 300.
  • the power supply system 300 is configured to pre -charge a capacitor Cm at the output of the rectifier 304 using the transformed power, using an AC bus pre-charge system 305, prior to turning on the rectifier 312.
  • the power supply system 300 is configured to pre-charge a capacitor Cm to a voltage that is higher than the turn-on voltage of the electrolyzer stack 310.
  • the power supply system 300 may use the charge of the capacitor Cm to pre-charge Com at the input to the electrolyzer stack 310 to the voltage that is higher than the turn-on voltage of the electrolyzer stack 310.
  • power supply system 300 may turn on the rectifier 312 and switch the output of the power supply system 300 from the output of pre-charge system 314 to the output of the rectifier 312.
  • a secondary winding of the transformer 303 may be configured to provide the voltage that is higher than the turn-on voltage of the electrolyzer stack 310.
  • a secondary winding of the transformer 303 is configured to provide the voltage that is higher than the turn-on voltage of the electrolyzer stack 310, less copper (and/or other raw material inputs) may be used and cost of the transformer 303 may be reduced as compared to a transformed used with power supply systems that pre-charge output of a rectifier to a turn-on voltage of an electrolyzer stack.
  • the resistor 316 may be sized to dissipate power and limit current up to 10% of the electrolyzer current during the startup transient.
  • the resistor 316 is sized such that the resistor is able to carry up to Iio% for the transient time, which is dominated by the time to charge the stack capacitance (in the range of 0.1 to 10 Farads) to Vio%.
  • Iio% is 2,000 A and the selected resistance of the resistor 316 is 100 mOhm
  • the initial voltage across the resistor 316 is 150mV (the differential voltage from Vtumon and Vio%).
  • the initial inrush current through the resistor is 1 ,5A and the initial power dissipation is only 0.2 W.
  • the electrolyzer stack capacitance RC time constant is then 0.2 sec. At the end of 1 sec, the stack capacitance may be largely charged, and the current through the resistor is then 2000A. In this case, the peak power dissipation in the resistor of 400kW.
  • the power supply system 300 may be designed to handle dissipation of 60 kWh during start-up of the electrolyzer stack 310.
  • Fig. 4 shows an illustrative example power supply system 400 for an electrolysis system, according to an embodiment.
  • the power supply system 400 is generally the same as the supply system 300 of Fig. 3, except that in the power supply system 400, instead of the resistor 316, a buck converter including a series inductor 416 is provided between the rectifier and the electrolyzer stack.
  • the inductor is properly sized to impede inrush current allowing the stack capacitance to charge up to Vio%.
  • the example power supply system 400 includes the buck converter connects the capacitor Cm to the electrochemical stack 310.
  • the buck converter may be configured to modulate current flowing through the inductor 416 to distribute heat dissipation due to current drawn by the load up to current that corresponds to the voltage that is above the turn-on voltage of the load over time. Due to the minimum back ratio of the buck converter, efficiency may be suitably high, and the cost may be low, in various embodiments.
  • the resistor 316 in the power supply 300 of Fig. 3 is bypassed with a contactor or solid state switch during normal operation past startup.
  • the inductor 416 in the power supply 400 of Fig. 4 is bypassed with a contactor or solid state switch during normal operation past startup, in an embodiment.
  • a simple contactor is used for the bypass without risk of arcing because the voltage across the resistor 302 and the inductor 402 is small.
  • the bypass requirement may be necessary because the power dissipation from such a resistor would be untenable in steady state operation, and the power rating of the resistor sized to 100% current would drive excessive cost.
  • the intrinsic series resistance of the inductor 416 generally drives the conductor size of the inductor 416.
  • cost of the power supply system 400 may be increased if the inductor 416 is designed to be left in-circuit.
  • a system in accordance with one aspect of the disclosure, includes an output port configured to be coupled to a load, the load having a turn-on voltage.
  • the system also includes a power converter configured to convert power from a power source to provide power to the load.
  • the system additionally includes a pre-charge system configured to pre-charge the load to a voltage that is higher than the turn-on voltage of the load prior to turning on the power converter such that the power converter is turned on during an operating mode of the load.
  • a method for providing power to a load by a power supply system includes pre-charging, by a pre-charge system, the load to a voltage that is higher than a start-up voltage of the load. The method also includes, when the load is pre-charged to the voltage that is higher than the turn-on voltage of the load, switching output of the power supply system from the pre-charge system to an output of a power converter. The method further includes, during operation of the load, controlling the power converter within a control range that begins at the voltage higher than the turn-on voltage of the load.
  • the power converter includes a boost power converter.
  • the load includes an electrolyzer stack.
  • the precharge system includes an inrush current limiter.
  • the pre-charge system includes a switched resistor provided between an output of the power converter and the input of the load, wherein the resistor is sized such that i) the load is pre-charged to the voltage that is above the turn-on voltage of the load ii) the resistor is able to handle current drawn by the load up to current that corresponds to the voltage that is above the turn-on voltage of the load.
  • the pre-charge system includes a buck converter including an inductor provided between an output of the power converter and the input of the load, wherein the buck converter is configured to modulate current flowing through the inductor to distribute heat dissipation due to current drawn by the load up to current that corresponds to the voltage that is above the turn-on voltage of the load over time.
  • the power converter is controllable within a reduced control range from current corresponding to the voltage that is higher than the turn-on voltage of the load to a maximum current required for the load.
  • the voltage that is higher than the turn-on voltage of the load corresponds to one of: 10% of the maximum current required for the load, 15% of the maximum current required for the load, 20% of the maximum current required for the load, 25% of the maximum current required for the load, and 30% of the maximum current required for the load.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Automation & Control Theory (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Dc-Dc Converters (AREA)

Abstract

Un système selon l'invention comprend un port de sortie configuré pour être couplé à une charge, la charge ayant une tension de seuil. Le système comprend également un convertisseur de puissance configuré pour convertir de l'énergie provenant d'une source d'alimentation pour fournir de l'énergie à la charge. Le système comprend en outre un système de précharge configuré pour précharger la charge à une tension qui est supérieure à la tension de seuil de la charge avant la mise à l'état passant du convertisseur de puissance de telle sorte que le convertisseur de puissance est mis à l'état passant pendant un mode de fonctionnement de la charge.
PCT/US2024/041685 2023-08-11 2024-08-09 Optimisation de convertisseur de puissance Pending WO2025038437A2 (fr)

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US202363532284P 2023-08-11 2023-08-11
US63/532,284 2023-08-11

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WO2025038437A3 WO2025038437A3 (fr) 2025-04-10

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9356536B2 (en) * 2013-01-11 2016-05-31 ABBI Research Ltd. Bidirectional power conversion with fault-handling capability
JP7124297B2 (ja) * 2017-10-31 2022-08-24 富士電機株式会社 電力変換装置
DE102018133641A1 (de) * 2018-12-27 2020-07-02 Sma Solar Technology Ag Elektrolysevorrichtung mit einem umrichter und verfahren zur bereitstellung von momentanreserveleistung für ein wechselspannungsnetz
DE102020103076A1 (de) * 2020-02-06 2021-08-12 Sma Solar Technology Ag Verfahren zur versorgung einer dc-last, energieumwandlungsanlage und elektrolyseanlage
DE102020111556A1 (de) * 2020-04-28 2021-10-28 Sma Solar Technology Ag Verfahren zur erweiterung eines dc-spannungsbereichs eines gleichrichters, gleichrichter zur durchführung des verfahrens und elektrolyseanlage

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