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Electrolyzer Characterization System 

The Electrolyzer Characterization System is a laboratory-grade platform designed for in-depth testing of PEM electrolyzers in green hydrogen generation. It features five stackable cells plus additional variable-area cells, powered by a programmable DC supply for precise I–V characterization. A distilled water system with conductivity sensors and peristaltic pumps ensures controlled water quality and flow, while gas handling units with dryers, separators, and flow meters provide accurate hydrogen and oxygen measurement. Operating conditions such as temperature, pressure, and flow rate can be independently adjusted and monitored via a PC-based control and logging interface. Built-in safety systems—including overpressure shutdowns, leak detectors, and solenoid cut-offs—guarantee secure operation, making the platform ideal for research on efficiency, degradation, and operational optimization of electrolyzers. 

Key Features

  • Electrolyzer Cell & Stack Configuration: Includes five stackable PEM cells plus three additional cells of varying sizes for comparative research.
  • Precise Power Control: Programmable DC supply (0–15 V, 0–100 A) with PC interface for I–V characterization and efficiency testing.
  • Water Management System: Integrated distillation unit, conductivity sensors, and peristaltic pumps for high-purity water delivery.
  • Gas Handling Units: Includes dryers, separators, flow meters, and pressure controllers for safe collection of H₂ and O₂.
  • Real-Time Monitoring: PC-enabled dashboard for live display and logging of temperature, flow, voltage, current, and pressure.
  • Safety First: Automatic shutdown on overpressure, hydrogen leak detection with alarms, and solenoid cut-off valves for safe operation.
  • Variable Control Parameters: Adjustable temperature, flow rate, voltage, current, and pressure for condition-based optimization.
  • Research Ready: Supports studies on efficiency, degradation, water quality impact, renewable coupling, and advanced control algorithms.
  • Data Logging & Analysis: Exportable data (.CSV) for visualization, comparison, and long-term performance tracking.
  • Renewable Integration: Can simulate fluctuating renewable inputs (solar/wind) for dynamic load response studies.
Ecosense

Learning Module 

Ecosense

Cell & Stack Characterization

  • Perform I–V characterization of single cells and multi-cell stacks.
  • Compare performance of electrolyzers with different active areas (20, 30, and 50 cm²).
  • Measure hydrogen output, efficiency, and energy conversion under controlled operating conditions.

Operating Conditions & Optimization

  • Study the effect of temperature, pressure, and water flow rate on hydrogen yield and purity.
  • Optimize system efficiency by adjusting voltage, current, and flow parameters.
  • Simulate dynamic load conditions from renewable sources to evaluate electrolyzer responsiveness.

Safety, Control & Research Applications

  • Validate automatic shutdowns, leak detection systems, and overpressure protections.
  • Implement and test PID or advanced algorithms for automated control of flow, temperature, and pressure.
  • Extend experiments to hydrogen storage integration, degradation studies, and techno-economic analysis of green hydrogen production.

Technical Description

  • The system operates by supplying precisely controlled DC power to PEM electrolyzer cells, initiating electrochemical splitting of water into hydrogen and oxygen.
  • Distilled water is fed to the electrolyzer through a controlled water management unit equipped with conductivity, level, and temperature sensors to ensure stable electrolysis conditions.
  • Individual electrolyzer cells can be tested independently or interconnected to form a multi-cell stack, enabling both single-cell and stack-level characterization.
  • Integrated heaters regulate cell temperature, allowing users to study temperature effects on voltage losses and hydrogen production efficiency.
  • Generated hydrogen and oxygen pass through gas–water separators and drying units, ensuring accurate flow measurement and purity assessment.
  • Mass flow controllers, pressure sensors, and flow meters continuously monitor gas output and operating conditions.
  • A PC-based control interface records voltage, current, temperature, pressure, and gas flow data in real time for analysis and visualization.
  • Built-in safety systems automatically shut down operation during over-pressure or hydrogen leak events, ensuring safe laboratory experimentation. 
Ecosense

Technical Specifications 

Ecosense

Electrolyzer & Power Section


ParametersSpecifications
Electrolyzer TypePEM electrolyzer, single-cell & stackable
Number of Cells5 stackable cells + 3 variable-area cells
Cell Voltage Range1.9 – 2.5 V per cell
DC Power Supply0–15 V, 0–100 A, PC-controlled

* specifications can be customized as per user's requirements.

Water, Gas & Thermal Management


ParametersSpecifications
Water SupplyDistilled water system with conductivity & level sensors
Water Flow RateProgrammable via peristaltic pump
Gas HandlingH₂ & O₂ separators, dryers, NRVs
Operating PressureUp to 5 bar (controlled)

* specifications can be customized as per user's requirements.

Instrumentation, Control & Safety


ParametersSpecifications
MeasurementsVoltage, current, temperature, pressure, gas flow
SensorsPT100 temperature, pressure sensors, flow meters
Data InterfacePC-based GUI, real-time logging (CSV)
Safety FeaturesHydrogen leak detection, over-pressure shutdown, alarms

* specifications can be customized as per user's requirements.

Real world impact across Campuses

Recent Installations

Ecosense installed Green Hydrogen Generation and Storage System at Anna University, Chennai

Ecosense installed Green Hydrogen Generation and Storage System at Anna University, Chennai

September 17, 2024

Anna University is one of the most sought-after universities in South India. Renowned for nurturing professionals equipped with advanced technical...

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Frequently Asked Questions

Electrolyzers are mainly classified into alkaline electrolyzers, PEM (Proton Exchange Membrane) electrolyzers, solid oxide electrolyzers (SOEC), and anion exchange membrane (AEM) electrolyzers. Alkaline systems are mature and cost-effective, PEM electrolyzers offer fast dynamic response and high purity hydrogen, SOECs operate at high temperatures for improved efficiency, while AEM electrolyzers aim to combine low cost with compact design.

A solid oxide electrolyzer operates at high temperatures, typically between 600 °C and 900 °C. Steam is supplied to the cathode, where it is reduced into hydrogen and oxygen ions. The oxygen ions migrate through a solid ceramic electrolyte to the anode, where oxygen gas is released. High-temperature operation reduces electrical energy demand by utilizing thermal energy.

An Electrolyzer Characterization System enables precise analysis of electrolyzer performance under controlled conditions. It allows users to study voltage–current behavior, efficiency, hydrogen production rates, and the effects of temperature, pressure, and water quality. The system supports safe, repeatable experiments and is ideal for academic research, technology comparison, and control strategy development.

The system is designed for laboratory-scale experimentation, so hydrogen output is limited compared to industrial plants. Initial setup and instrumentation costs can be higher than basic training kits. Additionally, accurate experimentation requires proper handling of sensors, water quality control, and safety protocols, which may demand trained operators.

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