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Materials of Construction for Electrolyzer Systems

Are there recommended resources that cover material stability for both PEM and alkaline electrolyzers at high pressures?

The answers are in context of PEM and alkaline electrolysis operating at or below 30 bar and below 85 deg C°. A general suggestion: Ask component suppliers about material compatibility, but do an independent investigation to confirm. As a general resource,  safety data sheets (SDSs) sometimes provide material compatibility information. Specific recommendations follow. 

  • Hydrogen: Hydrogen material compatibility information can be found at Material Compatibility Hydrogen Tools (h2tools.org), including the very detailed technical reference developed by Sandia National Laboratories.
  • Alkaline Water Electrolysis Systems: Cell stack electrolytes are typically potassium hydroxide, sodium hydroxide, or sodium chloride solutions. The pumps, piping, gas/liquid separators, and other components must be compatible. An example of an MSDS that provides information about material compatibility can be found at ERCO Worldwide: Potassium Hydroxide Solution.  Other resources include publications by the National Association of Corrosion Engineers and the Materials Technology Institute.
  • Oxygen: Oxygen compatibility is a big concern, especially at pressure. ASTM subcommittee G04.02 affords no-cost access to apt standards and cleaning practices for oxygen. Start here: ASTM International Jurisdiction of G04.02. Other resources include CGA G-4.4, Oxygen Pipeline and Piping Systems. Only certain materials are rated for pressurized oxygen. Cleaning to remove particles and oils is very important to reduce fire hazards - remember, almost anything can be fuel in oxygen. 
  • Water: Pure water feed to electrolyzers is important. A good approach is to consult with the water purification equipment supplier for recommended materials for the feed water supply components. High purity water corrosion products can contaminate PEM membranes and degrade electrolyte. 
  • The use of plastic tubing in H2 and O2 pressure applications is usually precluded. See the AICHE CHS H2 Laboratory Safety course, which discusses a PNNL laboratory incident. Metal tubing is preferred. While plastic tubing may be desirable for non-conductivity and flexibility, one should only consider plastic tubing after a full hazard analysis to assure there are effective protective safeguards (e.g., ventilation, flow limits, protective enclosures, active leak detection, isolation/depressurization) in place. 
  • H2 and O2 gases dissolve in significant quantities in liquids at 30 bar. Materials in these services will need to be compatible with the gas as well as the fluid. Note that these gases will readily come out of solution when pressure is reduced and directed to a drain. Open drains in well-ventilated areas are strongly recommended.

Pay particular attention to material compatibility of safety devices, such as pressure relief valves and pressure sensors. It is important to follow the guidance for proper design of vent systems given in CGA G 5.5 for H2 and EIGA Doc 154 for O2. These standards cover topics such as where back pressure is to be avoided and safe vent locations.
 

FAQ Category
Submission Year
2023
Month
08

Torch Assembly Components

Are there generic recommendations for setting up an oxygen/hydrogen torch assembly, for example, to fuse quartz tubes? Of particular interest are the locations of check valves, excess flow control valves, and flash arrestors.

Precautions applicable to oxy-acetylene torches are likely applicable here and are a good starting point. Recommendations for the hardware are best provided by the cylinder supplier, and all these parts can be purchased from their respective catalog. All three devices in the question should have UL listings, FM approvals, or some other nationally recognized testing laboratory (NRTL) listing, which should include limitations on effective placement of these devices on the fuel line. Inquire with the valve/arrester supplier/manufacturer to see the listing and go to the NRTL web site that describes the basis and limitations of the listing, particularly its use with hydrogen.

FAQ Category
FAQ Keyword
Submission Year
2024
Month
05

Flammability Limits - Mixtures

Is there a reference that quantifies the effects of pressure and temperature on the flammability limits of hydrogen/oxygen mixtures?

H2-air flammability limits vary with temperature  . The H2-air lower flammability limit is virtually the same as the H2-O2 lower limit. However, the H2-O2 upper flammability limit increases substantially to about 95% at room temperature and gets even higher at elevated temperatures.

 

FAQ Category
Submission Year
2024
Month
04

Storage Vessels

What safety risks arise from oxygen enriched liquefied air formation due to failure of the insulation on a liquefied hydrogen system and what measures can be taken to minimize the consequences of those risks?

This can be a complex problem and response to insulation failure should be considered in the emergency response guidelines and procedures. 
First, a tank with an insulation failure may boil off at an elevated rate which applicable codes build into the relief device and vent system design.
Second, ice and oxygen enriched liquefied air can form where inadequately insulated surfaces are exposed to air. Ice is the most likely symptom of insulation failure, and this can lead to various issues such as higher probability of seal leaks, additional weight loads on piping, and frost heaving of the foundation. Loss of vacuum insulation rarely leads to creation of liquified air, but as a precaution, any material that could be exposed to liquid air must be compatible for both oxygen and cryogenic hazards. For example, flammable materials such as asphalt are not permitted below LH2 systems. 

FAQ Category
FAQ Keyword
Submission Year
2024
Month
04
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