Process Flow Diagram

Block Flow Diagram
Electrostatic Filter Carbon Filter Demister
High Pressure
Hydrogen separator
Electrolyzer
TSA dryer
Low pressure
Hydrogen Separator
Hydrogen Storage Compressor
Hydrogen Production from Atmospheric Moisture
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Credits: Visual Paradigm Opensource BFD Maker
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Process Description
The concept of producing hydrogen gas (H2) from atmospheric moisture
through electrolysis is a groundbreaking endeavor at the forefront of
sustainable energy innovation. This process, powered by renewable
energy sources like solar or wind, is poised to reshape the future of clean
energy production, incorporating fundamental chemical engineering
principles.
Atmospheric Moisture Capture

Before delving into the core electrolysis process, it's crucial to address the
mechanism for capturing atmospheric moisture. This step typically
involves an array of moisture-absorbing materials or membranes
specifically designed to draw water vapor from the ambient air. This
innovative moisture capture technology enables the utilization of the
naturally occurring moisture in the atmosphere as a feedstock for the
subsequent hydrogen production process.
Power Electronics and Electrical Chemistry

At the very core of this transformative process lies power electronics,
including transformers and rectifiers. These components are responsible
for converting incoming alternating current (AC) power into finely
regulated direct current (DC). This DC power serves as the lifeblood of
the entire operation, providing the essential energy required for the
electrolysis process.
Electrolyzer Stack and Electrochemical Reactions

The beating heart of the system is the electrolyzer stack, comprised of
multiple cells meticulously designed to optimize the efficiency of the
hydrogen production process. Each cell facilitates electrochemical
reactions that play a critical role in converting water vapor into hydrogen
and oxygen gases. Under the influence of applied DC electricity, the water
molecules disintegrate into hydrogen (H2) and oxygen (O2) gases. This
process of water electrolysis leverages chemical engineering principles to
maximize the yield of high-purity gases.
Gas/Water Separators and Heat Exchangers
Positioned strategically above the electrolyzer stack are gas/water
separators, designed with heat exchangers and baffles to cool the
electrolyte and reduce the aerosol content within the resultant hydrogen
and oxygen gases. Chemical engineering principles of phase separation
and heat transfer optimization come into play here, ensuring the efficient
separation and cooling of gases and liquids.
Demisters, Control Valves, and Gas Scrubber

Subsequent to the separation phase, the system deploys demisters or
coalescent filters to capture liquid droplets. Control valves are positioned
to maintain optimal pressure levels within the system. To guarantee the
purity of the hydrogen gas produced, a gas scrubber is employed,
applying chemical engineering principles of absorption and mass transfer
to efficiently remove impurities and moisture from the hydrogen gas
stream.
Electrolyte Management
The management of the alkaline solution, typically potassium hydroxide
(KOH), involves chemical engineering concepts such as mass balance
and concentration control. The feed water system, with its pump, plays a
pivotal role in sustaining a consistent concentration of the electrolyte,
preventing fouling within the system, and ensuring long-term reliability and
efficiency. Deionization of the feed water adds an additional layer of
chemical engineering sophistication to maintain optimal conditions.
Heat Exchangers and Temperature Control

An array of heat exchangers is seamlessly integrated into the system to
manage temperature levels. Chemical engineering principles of heat
exchange and thermodynamics are applied to maintain optimal conditions
for both the electrolyte and gases, contributing to overall system efficiency
and safety.
Hydrogen Production and TSA Dryer Integration:
As the process advances toward the hydrogen production stage, the dry
air from the TSA dryer plays a critical role. This dry air is channeled into
the electrolyzer stack, where water vapor extracted from the atmosphere
is transformed into high-purity hydrogen gas and oxygen gas through
water electrolysis. The dry air helps maintain optimal conditions within the
electrolyzer stack, ensuring efficient and consistent hydrogen production.
Gas Reservoir and Storage Principles

In order to ensure a steady supply of hydrogen for downstream
applications, a low-pressure gas reservoir designated for hydrogen
storage is incorporated. This reservoir applies chemical engineering
principles of gas storage and pressure regulation to guarantee a
consistent and reliable flow of hydrogen gas, even when fluctuations occur
during the electrolysis process. By integrating the TSA dryer into the
atmospheric moisture capture process, this innovative technology
enhances the overall efficiency of moisture extraction and contributes to
the production of high-quality, clean hydrogen fuel, thus furthering the
goals of sustainable and eco-conscious energy production.
Thermodynamic Model selection
Considering that the process involves moisture capture, electrolysis,
phase changes, and heat exchange, a comprehensive approach is
needed:
Electrolyte Thermodynamics: Given the presence of an electrolyte
(potassium hydroxide, KOH), utilizing models like the Pitzer or Debye-
Hückel equations would be essential. These models account for ion
interactions and activities in the electrolyte solution, ensuring accurate
representation.
Ideal Gas Model for Gases: For hydrogen and oxygen gases, especially
in the early stages of the process, the ideal gas model can be sufficient.
This simplifies calculations and is appropriate when pressures and
temperatures are relatively low.
Phase Equilibrium Models: When gases separate from the liquid
electrolyte, phase equilibrium models like Raoult's law or Henry's law
should be employed to capture the phase changes accurately.
Kinetic Models for Electrolysis: To model the kinetics of the electrolysis
reactions, consider incorporating kinetic models like the Butler-Volmer
equation or Tafel equation. These will help represent the rate of reaction
accurately.
Heat Transfer and Heat Exchanger Models: For components involving
heat transfer, such as heat exchangers, use appropriate heat exchanger
models like the effectiveness-NTU method to analyze heat transfer and
temperature control.

Process Flow Diagram

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Process Flow Diagram

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Block Flow Diagram

Electrostatic Filter Carbon Filter Demister

Hydrogen Storage Compressor

Hydrogen Production from Atmospheric Moisture

HPHS- Hgh pous

Atmospheric Moisture Capture

Power Electronics and Electrical Chemistry

Electrolyzer Stack and Electrochemical Reactions

Demisters, Control Valves, and Gas Scrubber

Heat Exchangers and Temperature Control

Gas Reservoir and Storage Principles

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