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Development of a low cost, portable solar hydrogen generation device

Article  in  Proceedings of SPIE - The International Society for Optical Engineering · October 2014
DOI: 10.1117/12.2061964

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Kyle Rose Mohan Aggarwal

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 Development of a low cost, portable solar hydrogen generation device
Kyle Rose1*, M. D. Aggarwal1, Ashok Batra1 and Dennis Wingo2
1
Department of Physics, Chemistry and Mathematics, PO Box 1268
Alabama A&M University, Normal, AL 35762 USA
2
Skycorp Inc., P.O. Box 375, Moffett Field, CA 94035 USA

ABSTRACT

Hydrogen is a clean energy source that is environmentally friendly and safe. It is well known that electrolysis is a common
method used to produce hydrogen. Other high cost methods for hydrogen production can be countered by the development
of this low cost pulse width modulated circuit, using direct current provided by naturally existing solar energy as a power
source. Efforts are being made in the scientific community to produce a low cost, portable, solar hydrogen generating
device for a number of clean energy applications such as fuel cells and energy storage. Proof of concept has already been
tested in the laboratory and a small prototype system is being designed and fabricated in the workshop at Alabama A&M
University. Our results of this study and details of the electronic circuit and the prototype are presented.

Key words: Solar energy, Hydrogen, Fuel Cells, Water electrolysis

1. INTRODUCTION

The quality and comfort of human life depends to a large degree on the availability of energy sources. The present annual
worldwide energy consumption has already attained a level of over 400 exajoules and is expected to further augment
steeply from the increase in world population and the rising demand of energy in the developing countries. This depletion
of fossil fuel reserves is leading to further aggravation of the environmental pollution. Quality of life on earth is threatened
unless renewable energy resources can be developed in the near future [1]. Using renewable energy sources has promising
options for energy; however, there are still major issues and concerns about some renewable energy sources and their
implementation, e.g. (i) capital costs, and their intermittent nature in power production. The requirement for a supply of
energy sources that are fully sustainable is the most important priority as it relates to our renewable energy future.
Renewable energy sources – such as wind and solar energies cannot produce steadily. Hydrogen appears to be an
environmentally benign and sustainable fuel. If hydrogen is produced from renewable energy sources and used in fuel
cells, the only by-product is heat and water. Various methods of making hydrogen from water have been proposed [2-3].
At the present time the only practical way to make hydrogen from water without fossil fuel is electrolysis. The development
of new, advanced, Water Electrolyzer has become necessary for use in hydrogen energy systems and in electricity storage
systems. All the new possible electrolysis processes, suitable for large-scale plants, are being analyzed, in view of their
combination with solar energy as an electricity source. Water electrolysis systems have no doubt had to be improved
considerably and are expected to become the principle means to produce a large amount of hydrogen in the coming
hydrogen economic age. Thus, the present paper treats the subject of hydrogen production efficiently from direct solar
energy conversion in small scale to show the concept with use of a novel converter circuit.

_________________________________
*Krose1@bulldogs.aamu.edu

Solar Hydrogen and Nanotechnology IX, edited by Sanjay Mathur, Proc. of SPIE Vol. 9176, 917606
© 2014 SPIE · CCC code: 0277-786X/14/$18 · doi: 10.1117/12.2061964

Proc. of SPIE Vol. 9176 917606-1

 2. EXPERIMENTAL

The use of a Pulse Width Modulation (PWM) solar hydrogen generation device centers on development of naturally
existing solar photonic energy as a renewable power source. Solar photonic energy provides voltage and current once
converted to electronic energy by a standard photovoltaic panel. In the laboratory a power supply will provide the
constant power source in place of the photovoltaic panel and battery power. The photovoltaic-electrolysis process
components (Figure 1) consist of a power source (photovoltaic module), power monitoring, regulation and storage
(charge controller and storage batteries), the DC/DC converter, and the electrolyzer consisting of stainless steel anode
and cathode electrodes [1]. Various types of electrolytes will be investigated including pure water and some salt
solutions to increase hydrogen production. The PWM circuit will ultimately interface to a photovoltaic panel, required
voltage monitoring and regulation components to produce 9 to 14 volts (15 volts maximum) and up to 11 amps
maximum input current. A timing circuit which utilizes amplification components and a unique point of load Direct
Current to Direct Current (DC/DC) converter to predictably produce a large enough current source (up to 16 amps) for
splitting water molecules [1] in various electrolyte solutions. The converter output voltage is precisely regulated at 0.75V
to 5.0Vdc volts.

H2
O2

Photovoltaic Charge Storage DC/DC Electrolyzer

Modules Controller Batteries Converter

Figure 1. Basic Components of the Photovoltaic-Electrolysis System

2.1 Description of Novel DC/DC converter circuit

As shown in the schematic (Figure 2), the PWM solar hydrogen generation device consists of a 12 volt input to a 555
timer circuit followed by switching and amplification transistors Q1 and Q2. Q3 and Q4 are 14 amp rated N-Channel
power Metal Oxide Silicon Field Effect Transistors (MOSFET) switching regulators. The DC/DC converter U2 is a
unique point of load converter that is employed to handle the solar panel input voltage and convert the provided energy
up to 16 amps to split water molecules for hydrogen production by the stainless steel electrodes. The electrodes will be
positioned in pure water or salt solution electrolyte to obtain the greatest hydrogen producing effect . Convection cooling
is required across the circuit board (Figure 3,4) during ranges of 6 amps to 16 amps current generation from 0 liquid flow
meters (LFM) to 300 LFM airflow in the temperature ranges of 30 oC to 90oC respectively. This circuit is cost effective,
94% efficient at 5 volts, has over temperature protection, continuous short circuit protection. The operating range is -40o
C to +85o C. The size of this portable solar hydrogen generating device will compromise or trade-off for hydrogen
production by the need of a high current low heat producing device that uses a standard solar panel voltage/current input.
This compromise can be seen in the balance of a wind turbine torque to overcome wind speed to power output. Monitor
temperature at pin 6 on Q1 and Q2 per (Figure 3).

Proc. of SPIE Vol. 9176 917606-2

Figure 2. Schematic diagram of the PWM solar hydrogen generation device

Figure 3. DC/DC Converter Convection Cooling Airflow

Figure 4. DC/DC Converter Convection Cooling Airflow Graph

Proc. of SPIE Vol. 9176 917606-3

To predict the approximate convection cooling requirements refer to the DC/DC Converter Convection Cooling Airflow
Graph in (Figure 4). Thermal considerations for power produced, cooling should be provided to make sure of reliable
operation of the device. Airflow should be parallel to the long axis. Heat is removed by conduction, convection, and
radiation to the surrounding environment. The efficiency verses load curves (Figure 5), shows 0.75 to 5.0 volts dc
regulated output efficiency verses the output current load.

Figure 5. Efficiency verses Load Curves

Proc. of SPIE Vol. 9176 917606-4

The basic set-up to measure efficiency is established with equation (1). Where VO is output voltage, IO is output current
Vin is input voltage and Iin is input current.

Vo x Io
= x 100% (1)
Vin x Iin

𝑉𝐹𝐿 x 𝑉𝑁𝐿
Load.reg = x 100% (2)
𝑉𝑁𝐿

Equation (2) shows load regulation where VFL is the output voltage at full load. VNL is the output voltage at no load. The
input and output share a common ground. The grounds are connected together as shown in (Figure 6) via a low
impedance ground plane. Testing the converter on a bench set-up, –Vin and –Vo are connected together via a low
impedance short to ensure proper efficiency and load regulation measurements are made. VO is output voltage, IO is
output current, Vin is input voltage, Iin is input current. The value of line regulation obtained by equation (3).
The value of line regulation is defined as:

𝑉𝐻𝐿 − 𝑉𝐿𝐿
Line.reg = x 100% (3)
𝑉𝐿𝐿
Where: VHL is the output voltage of maximum input voltage at full load. VLL is the output voltage of minimum input
voltage at full load.

Figure 6. Series Test Bench-Setup.

Proc. of SPIE Vol. 9176 917606-5

 3. RESULTS AND CONCLUSIONS

A clean energy low cost pulse width modulated circuit device has been designed and fabricated. The device produces
hydrogen from a clean energy source that is environmentally friendly. Preliminary results of the circuit operation are
satisfactory and are presented. The hydrogen produced can provide a number of clean energy applications such as fuel
cells [5], stationary structures that use fuel cells [6], and energy storage.

ACKNOWLEDGEMENTS

We are thankful for the support and resources of Dr. Chance Glenn, Dean of the College of Engineering Technology and
Physical Sciences, Alabama A&M University. I thank Anthony Brown (1963-2011) for his support, inspiration and
partnership in the PWM circuit design and part procurement. The financial support for this work is gratefully
acknowledged. Also the work was partially supported by NSF subcontract #083052T6181283 and ASGC NASA training
grant #NNX10AJ80H. One author wishes to acknowledge support of NSF-MSP APEX project #1238192.

REFERENCES

[1] M. Gratzel, “Mesoscopic solar cells for electricity and hydrogen production,” Chemistry Letters, 34 (1), Pages 8-13,
(2005).

[2] E. Bilgen, “Solar hydrogen from photovoltaic-electrolyzer subsystem,” Energy Conversion and Management, Volume
42, Pages 1047-1057, (2001).

[3] T. L. Gibson and N. A. Kelly, “Optimization of solar powered hydrogen production using photovoltaic electrolysis
devices,” International Journal of Hydrogen Energy, 33, Pages 5931-5940, (2008).

[4] Dharmaraj C.H, AdishKumar S., “Economical hydrogen production by electrolysis using nano pulsed DC,” Energy
and Environment, Volume 3, Issue 1, Pages 129-136, (2012).

[5] Rene B. LaPierre, Randall D. Partridge, “Method and system for supplying hydrogen for use in fuel cells,” Mobil Oil
Corporation, Patent US6348278, 1/22, (2002).

[6] S. Ahmed, M. Krumpelt, “Hydrogen from hydrocarbon fuels for fuel cells,” International Journal of Hydrogen
Energy, Volume 26, Issue 4, Pages 291-301, (2001).

Proc. of SPIE Vol. 9176 917606-6

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