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Hydrogen produced through electrolysis, known as “Green Hydrogen”, is currently inefficient and costly compared to conventional methods like steam reforming or coal gasification. The inefficient operation of an electrolyser generates heat as a byproduct, which needs to be rejected or utilised. A research project was conducted to highlight the causes of inefficiencies in green hydrogen production as well as strategies for managing heat. A literature study and mathematical modelling in MATLAB served as the basis for the design of a small, alkaline electrolyser that was manufactured and tested. Experimental testing confirmed predictions from modelling that the electrolyser is more efficient at high stack temperatures, but design deficiencies caused excess generation of heat and ineffective rejection of this heat. Additionally, general design principles with regards to the material and geometry of an alkaline electrolyser were clarified by analysing the performance of the designed electrolyser.

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Design, Manufacture and Testing of a Small-Scale, Alkaline Electrolyser to Highlight Efficiency and Thermal Management Principles in Green Hydrogen Production

  • 会议论文

  • 发表日期：

    2026年

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  • Johannes A. Steenkamp,
  • Hanno Reuter

摘要

Hydrogen produced through electrolysis, known as “Green Hydrogen”, is currently inefficient and costly compared to conventional methods like steam reforming or coal gasification. The inefficient operation of an electrolyser generates heat as a byproduct, which needs to be rejected or utilised. A research project was conducted to highlight the causes of inefficiencies in green hydrogen production as well as strategies for managing heat. A literature study and mathematical modelling in MATLAB served as the basis for the design of a small, alkaline electrolyser that was manufactured and tested. Experimental testing confirmed predictions from modelling that the electrolyser is more efficient at high stack temperatures, but design deficiencies caused excess generation of heat and ineffective rejection of this heat. Additionally, general design principles with regards to the material and geometry of an alkaline electrolyser were clarified by analysing the performance of the designed electrolyser.