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Abstract This study provides an experimental validation of a multiple‐input multiple‐output (MIMO) model predictive control (MPC) strategy, coupled with dynamic risk modeling, to address two critical aspects of proton exchange membrane water electrolysis (PEMWE) operation: (i) process safety, by mitigating temperature imbalances, and (ii) system performance, through precise hydrogen production control. A cyber‐physical platform was developed for real‐time monitoring, state‐space modeling and validation, risk metrics analysis, control implementation, and visualization. Open‐loop experiments revealed limitations in managing thermal gradients, underscoring the need for feedback operating strategies. The proposed closed‐loop MPC approach achieved precise tracking of hydrogen production while maintaining safety by ensuring temperature stability. Moreover, the dynamic risk metrics show how thermal risk evolves with temperature and offer guidance for decision‐making. These findings demonstrate the effectiveness of MIMO MPC in enhancing the operational safety and efficiency of PEMWE systems, providing a foundation for scalable and sustainable hydrogen production.
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This content will become publicly available on July 1, 2026
Model-based Operability and Safety Optimization for PEM Water Electrolysis
In this paper, we present a systematic approach to quantify the safe operating window of a proton exchange membrane water electrolysis (PEMWE) system considering energy intermittency and varying hydrogen demand. The PEMWE model has been developed based on first principles, with the polarization curve validated against a lab-scale experimental setup. The impact of key operational variables is investigated which include voltage, inlet temperature, and water flowrate (utilized for both feed and system cooling). Emphasis is given on operating temperature, a safety-critical variable, as its elevation can pose significant hydrogen safety risks within both the electrolyzer cells and the storage system. The impact of temperature on process safety is quantified via a risk index considering the fault probability and consequence severity. Process operability analysis is employed to assess the achievability of a safe and feasible region for design and operations. This analysis provides a comprehensive framework to optimize PEMWE systems for enhanced operational flexibility and robust performance with application to modular hydrogen production using renewable energy sources.
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- Award ID(s):
- 2312457
- PAR ID:
- 10627636
- Publisher / Repository:
- PSE Press
- Date Published:
- Page Range / eLocation ID:
- 2007 to 2012
- Format(s):
- Medium: X
- Location:
- Ghent, Belgium
- Sponsoring Org:
- National Science Foundation
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