集装箱式水电解制氢设备

Container type hydrogen production equipment by water electrolysis

集装箱式水电解制氢设备：电解槽、框架、纯化设备、控制柜、整流柜、变压器集中安装于一个或两个集装箱内

一，技术参数 
1  氢气产量：10-200Nm3/h 
2  氧气产量：5-100Nm3/h 
3  氢气纯度：≥99.8-99.999%

4  氧气纯度：≥99.2% 
5  氢气湿度：＜4mg/m3 
6  电解槽额定工作压力：1.6-3.2MPa 
7  电解槽工作温度：＜90℃ 
8  电解槽电解小室工作压力：～2V 
9  电解槽单位产氢量直流电耗：4.6kW.h/Nm3 


二，工艺流程简介

生活自来水经纯水装置处理制取纯水，并送入原料水箱，经补水泵输入碱液系统，补充被电解消耗的水。电解槽中的水，在直流电的作用下被分解成H2与O2，并与循环电解液一起分别进入框架中的氢、氧分离洗涤器后进行气液分离、洗涤、冷却。分离后的电解液与补充的纯水混合后，经碱液冷却器、碱液循环泵、过滤器送回电解槽循环，电解。调节碱液冷却器冷却水流量，控制回流碱液的温度，来控制电解槽的工作温度，使系统安全运行。分离后的氢气由调节阀控制输出，经氢气纯化装置纯化后，送入氢气储罐，再经缓冲减压后供用户使用。

集装箱式水电解制氢设备具有土建量小，便于安装和移动等优点，用户只需要接入水、电、气即可随时随地制氢，纯氢制氢量可高达5-200Nm3/h每套；  

集装箱式水电解制氢设备安装在一个集装箱内，简化了现场安装的过程。由带有电解槽的制氢系统，带有交流/直流转换的电源控制系统以及其他所需附件组成。工作压力可达1.6Mpa，氢气纯度可达99.999%。 

三，安全性和可靠性为目标： 

 1 测点设置：系统测点设置齐全，影响系统安全稳定运行的量均设置了上限或下限。除系统中的常规控制测点外，仪用气源压力设置控制测点，自动操作阀设有阀位反馈，使系统在水、电、气都合格的情况下运行，保证了阀门及仪表动作的正确性和出现故障时提示并在影响系统安全运行时联锁停机，保障系统安全运行。 
    2 自动运行：系统只要具备开机条件，只需点击开车按钮，系统自动检测各参数的正确性，以最优值自动升压、升流，自动开启除盐水冷却装置，自动投运分析仪表，自动补水，系统全自动运行。停车后自动切断整流柜电源和工业冷却水，自动停运分析仪表。 
3、安全性 
   3.1 冗余设计。特殊参数的监控采用各自独立的硬件回路，关系到系统的安全运行的回路采用冗余； 
   3.2 完善的联锁报警功能。与系统安全运行有关的参数均设置了报警和联锁功能，以保障系统安全运行，相应的调节上、下限，报警上、下限，联锁上、下限均可根据用户的需要进行在线调整。一旦系统发生超限联锁，则系统整流柜停机，且分阶段对系统进行安全降压，如果中途故障消除，则系统又会自动投入正常运行。 
4 、人性化的人机界面 
   人机界面分主流程、干燥纯化流程、直方图、趋势图、历史曲线主画面和调节设定、整流设定、联锁设定、报警设定、打印设定等参数设定子画面，按钮操作均有后果提示以利人员进行操作时充分理解操作意图从而避免误操作； 
   所有与运行有关的参数均可在上位机上方便地进行设定而不是固化在下位机PLC程序内，虽增加了编程的难度和成本，但最大限度地满足不同条件下系统运行的需要和完善、友好的人机接口； 
所有与系统安全运行有关的参数均设置了上下限，超过上下限的参数系统均提示非法参数并不予接受，避免误操作的情况发生。使监控人员能及时发现报警信息； 
自动阀门、各泵等均设置了手动/自动功能，每项报警、联锁均可人为屏蔽，实现不关键部件出现问题时仍能安全、自动运行。 
5、完善的调节策略 
   系统的调节策略直接影响到系统的调节品质、稳定性和安全性，因此，在编程环节中对调节给予了高度重视，在充分研究制氢设备的调节特点，并综合对系统调节影响有关的参数后，采用了多冲量的调节模式而非类似单回路控制器的调节模式，将其它有关参数对调节的影响进行了充分地考虑，制定出完善的调节策略并贯彻到程序的编制中，配合高品质的硬件，使系统的调节稳定、可靠，最大限度地保障了设备的安全、自动运行。 


四，制氢原理

在充满氢氧化钾的电解槽中通入直流电，水分子在电极上发生电化学反应，分解成氢气和氧气。其化学反应式如下 ： 

阴 极：2H2O+2e          H2↑ +2OH

阳 极： 2OH—2e        H2O+1/2O2↑

总反应式：2H2O        2 H2↑+ O2↑

根据库仑定律，气体产量与电流成正比，与其它因素无关。氢氧化钾的作用在于增加水的电导，本身不参加电解反应，理论上是不消耗的。电解液中加入五氧化二矾的作用是在于降低电解电压。单位气体产量的电耗，取决于电解电压，电解槽的工作温度越高，电解电压越低，同时也增加了对电解槽材料，主要是隔膜材料的腐蚀。石棉在碱液中长期使用温度不能超过100℃，因此操作温度选择在80~85℃为宜。电解压力的选择主要根据用氢的需要。气体纯度决定于制氢机结构和操作情况。在设备完好操作压力正常的条件下，纯度是稳定的。

五，设计工作参数：

1原料水（电解用水）：

要求：二次蒸馏水（或去离子水），电阻率＞2.0×105Ω٭cm；氯离子含量＜2mg/l；悬浮物＜lmg/l，按实际经验，原料水设备能力应为2—8小时产量供水电解24小时使用量。

2电解液：26%KOH水溶液

3控制柜电源：三相四线制AC  Container type water electrolysis hydrogen production equipment: Electrolyzer, frame, purification equipment, control cabinet, rectifier cabinet and transformer are installed in one or two containers, technical Parameters 1 hydrogen gas production: 10-200 NM 3 / h 2 oxygen production: 5-100 NM 3 / h 3 hydrogen purity: ≥99.8-99.999% 4 oxygen purity: ≥99.2% 5 hydrogen humidity: < 4 mg / M 36 cell rated working pressure: 1.6-3.2 MPA 7 cell working temperature: < 90 °C 8 cell working pressure: 2V 9 cell unit hydrogen production DC power consumption: 4.6 kw. H / NM32, process brief introduction, tap water is treated by pure water device to produce pure water, and fed into raw water tank, then fed into lye system by make-up pump to replenish water consumed by electrolysis. The water in the ELECTROLYZER is decomposed into H2 and O2 under the action of direct current, and then enters into the hydrogen and oxygen separation scrubber in the frame separately with the circulating electrolyte for gas-liquid separation, washing and cooling. After the separated electrolyte is mixed with the added pure water, it is sent back to the electrolyzer by the Alkali Cooler, the Alkali circulating pump and the filter for electrolysis. Adjust the cooling water flow rate of Lye Cooler, control the temperature of Return Lye, to control the working temperature of Electrolyzer, make the system run safely. The separated hydrogen is controlled by a regulating valve, purified by a hydrogen purification device, fed into a hydrogen tank, and then buffered and decompressed for use by users. With the advantages of small quantity of civil construction, easy installation and movement, the container type water electrolysis hydrogen production equipment can produce hydrogen anytime and anywhere, and the pure hydrogen production capacity can be as high as 5-200Nm3 / h per set only by connecting water, electricity and gas The containerized water electrolysis hydrogen production equipment is installed in a container, which simplifies the field installation process. Consists of a hydrogen production system with ELECTROLYZER, power supply control system with AC / DC converter and other required accessories. The working pressure can reach 1.6 MPA and the purity of hydrogen can reach 99.999% . Third, security and reliability as the goal: 1 Measurement Point Settings: The system measurement point settings are complete, affect the safe and stable operation of the system are set up the upper limit or the lower limit. In addition to the conventional control measurement points in the system, the instrument uses gas pressure to set control measurement points, and the automatic operating valve has valve position feedback to make the system run under the condition that water, electricity and gas are all qualified, ensure the valve and instrument action of the correct and fault prompt and affect the safe operation of the system when the interlock shutdown to ensure the safe operation of the system. Automatic Operation: As long as the system has the condition of starting up, just click the start button, the system automatically detects the correctness of the parameters, automatically raises the pressure and the flow with the optimal value, automatically opens the desalting water cooling device, automatically puts into operation the analysis instrument, automatically replenishes the water, the system is fully automated. Automatically cut off the power supply and industrial cooling water of the rectifier cabinet after stopping operation, and automatically shut down the analyzer. 3. Security 3.1 redundancy design. The special parameters are monitored by independent hardware loop, which is related to the redundancy of the safe operation loop of the system. 3.2 perfect interlock alarm function. The parameters related to the safe operation of the system are provided with alarm and interlock functions to ensure the safe operation of the system. The upper and lower limits of alarm, upper and lower limits of interlock can be adjusted on-line according to the needs of users. Once the system has out-of-gauge interlock, the system rectifier is shut down and the system is decompressed in stages. If the fault is eliminated, the system will be put into normal operation automatically. 4. Human computer interface, the man-machine interface is divided into main flow, drying purification flow, histogram, trend chart, main picture of history curve and adjustment setting, rectification setting, interlock setting, alarm setting, print setting, etc. , button operation has consequences to prompt the operator to fully understand the intention of the operation to avoid misoperation; All the parameters related to operation can be set conveniently on the upper computer instead of being fixed in the PLC program of the lower computer, although it increases the difficulty and cost of programming, however, it can meet the needs of the system operation under different conditions and has perfect and friendly man-machine interface, and all parameters related to the safe operation of the system are set up upper and lower limits, the parameter system that exceeds the upper and lower limits indicates that the illegal parameter is not accepted to avoid misoperation. So that the monitoring personnel can find the alarm information in time, the automatic valves and pumps are set up with manual / automatic functions, each alarm, interlock can be shielded manually, to achieve the non-critical parts of the problem can still be safe and automatic operation. 5. The perfect regulation strategy, the regulation strategy of the system directly affects the regulation quality, stability and safety of the system, therefore, the regulation is paid great attention in the programming link, and the regulation characteristics of the hydrogen production equipment are fully studied, after synthesizing the parameters related to the regulation of the system, the multi-impulse regulation mode is adopted instead of the regulation mode similar to the single-loop controller, and the effects of other relevant parameters on regulation are fully considered, the perfect regulation strategy is worked out and carried out in the programming. The high-quality hardware makes the regulation of the system stable and reliable, and ensures the safety and automatic operation of the equipment. Fourth, the principle of hydrogen production, in a potassium hydroxide electrolyzer into a direct current, water molecules on the electrode electrochemical reaction, decomposition into hydrogen and oxygen. The chemical equation is as follows: Cathode: 2H2O + 2e H2 + 2OH ANODE: 2OH Foshan 2E H2o + 12o2 total reaction formula: 2H2O 2h2 + O2 according to coulomb law, gas output is proportional to the current, independent of other factors. The effect of potassium hydroxide is to increase the conductivity of water, which itself does not take part in the electrolytic reaction and is theoretically not consumed. The effect of adding dichromate pentoxide to the electrolyte is to reduce the electrolytic voltage. The electricity consumption per unit gas output depends on the electrolytic voltage. The higher the working temperature of the electrolytic cell is, the lower the electrolytic voltage is. The temperature of asbestos can not exceed 100 °C for long-term use in Lye, so the operating temperature should be 80 ~ 85 °C. The selection of electrolytic pressure is mainly based on the need for hydrogen. The purity of the gas depends on the structure and operation of the hydrogen generator. The purity is stable under the condition that the equipment is in good working condition and the pressure is normal. 5. DESIGN PARAMETERS: 1 Raw Water (Electrolytic Water) : Requirements: Secondary distilled water (or deionized water) , resistivity > 2.0105 cm, chloride ion content < 2mg / l, suspended matter < LMG / l, according to practical experience, rAW WATER EQUIPMENT CAPACITY SHOULD BE 2 ~ 18 hours of water supply electrolysis 24 hours of use. 2 Electrolyte: 26% Koh aqueous solution 3 CONTROL CABINET POWER SUPPLY: THREE-PHASE FOUR-WIRE AC 380V