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Pressure Electrolyser
Based on the LURGI System
Overview
Pressure electrolysis is a established process for the production of
high-purity hydrogen and oxygen from water. This Process has
compared to atmospheric electrolysis the advantage that the
product gases are available at a pressure of 30 bar as generated.
As a result the hydrogen and oxygen are directly usable for most
applications an do not require any separate compression.

The design of the Lurgi System pressure electrolyser Systems is


distinguished by advance engineering, high reliability, convenient
operation and a long life span. They are backed by decades of
experience in the construction an commissioning of pressure
electrolysis plants.
Bipolar Cells in filter-press type assembly
Electrodes made of steel with new galvanic protection activation and
increase of the geometric and active electrode surface
Improved construction of the cell block parts like cell-frame, cellplate and pre-electrodes. Designed for lower current resistance and

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increased active surface area. Produced without thermal and forming


process related tension
Pressure process results in very compact equipment design. A large
number of cells can be arranged in line and large quantities of
hydrogen can generated in a single unit of low space requirements
Electrolyte used is 25% potassium hydroxide solution
Forced circulation of electrolyte provides for optimum heat
dissipation an uniform electrolyte concentration in all cells
Separation of gas and electrolyte takes place in horizontal separators
fitted with special internals to reduce aerosol level in product gases

Advantages
The pressure electrolyser have many advantages that ensure a
sophisticated and trouble-free hydrogen & oxygen production.
The major advantages are:

Pressure operation results in low specific energy consumption


Very low level of aerosols in product gases. Scrubbing of gases to
clean them of KOH is not required
Hydrogen and oxygen are available at 30 bar pressure. No
compressor required for storage and use of the product gases at this
pressure, saving approx. 0,2 kWh/Nm3 H2 energy for compression
Capacities up to 1400 Nm3/h H2 accommodated in a single
electrolyser, resulting in very small space requirements, low building
construction costs and reduced maintenance expenditure
Easy and secure operation due to extensive automation
High availability of equipment together with extensive flexibility and
long life
Convenient installation of factory-assembled cell blocks
Very high environmental compatibility. The only operating
consumables required are water and electricity

Range of Supply
The pressure electrolysers are built in unit capacities of 200 to
1400 Nm3/h hydrogen output and 100 to 700 Nm3/h oxygen
output. Larger capacities are readily obtained by operating a
multiple number of units in parallel.
The capacity of the pressure electrolysers is matched to the given
gas demand by just modifying the number of cells. These cells are
factory-assembled as blocks of the required size.

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ELB supplies the engineering and equipment for complete


pressure electrolysis plants and undertakes on-site installation and
commissioning. In addition to the electrolyser, The overall plant
comprises:

Modern signaling and monitoring system


Transformer/Rectifier
Feed water system
Electrolyte station
Gas and electrolyte coolers

Auxiliary equipment to suit the intended use of the product


hydrogen and oxygen is also available, including:
Catalytic gas purifiers for the production of highest purity H 2 and
O2 (residual impurities < 1 ppm)
Gas dryers to reduce residual moisture to dew points as low as -70C
Gas compressors, for instance to deliver gas at bottling pressure
(200 bar)
Gas bottling units and/or storage tanks

Operating Data

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Hydrogen and oxygen are generated at a pressure of 30 bar.


Gas purities
Hydrogen:
Oxygen:

99,8 99,9 vol%


99,3 99,6 vol%

Residual impurities in product gases:


O2 in H2:
0,1 0,2 vol%
H2 in O2:
0,4 0,7 vol%
H2O:
approx. 1 2 g/Nm3
KOH:
< 10 mg/Nm3 H2
The product gases are free from CO, CO2, CH4 and sulphur or
chlorine components.
Utilities consumption
Energy:
4,3 4,65 kWh/Nm3 H2
(gas at 0C, 1013 mbar, dry)
Feed water:
Cooling water:

0,85 l/Nm3 H2
80 l/Nm3 H2

Gas production rate is variable between 25% and 100% of the


nominal capacity on every electrolyser.
Maintenance
The pressure electrolysers are designed for many years of
uninterrupted operation and are essentially free from maintenance
requirements.
Plants now in service have been operating for more than 20 years
without the cells having to be opened during the time.
ELB can offer you full after-sales services from inspections,
maintenance support, qualified advices if any problems arise to
optimisation of operating parameters.