Design and experimental validation of a high voltage ratio DC/DC converter for proton exchange membrane electrolyzer applications

This paper deals with hydrogen production via water electrolysis, which is considered the most attractive and promising solution. Specifically, the use of renewable energy sources, such as wind electric power generators, is hypothesized for supplying the electrolyzer, aiming to strongly reduce the environmental impact. In particular, micro-wind energy conversion systems (?WECSs) are attractive for their low cost and easy installation. In order to interface the ?WECS and the electrolyzer, suitable power conditioning systems such as step-down DC-DC converters are mandatory. However, due to the requested high conversion ratio between the DC bus grid, i.e. the output of a three-phase diode rectifier connected to the output of the electric generator, and the rated supply voltage of the electrolyzer, the classic buck converter alone is not suitable. Therefore, a converter is proposed and designed, consisting of a buck converter, a full-bridge IGBT converter, a single-phase transformer, and a diode bridge rectifier; LC filters are also included between buck and full-bridge converters, and at the output of the diode bridge rectifier with the aim of reducing the ripple on currents and voltages. The components of the described physical system from the output of the three-phase rectifier up to the electrolyzer are then modeled assuming the transformer as ideal, and the model is employed for designing a PI-type controller. Experimental results are provided in order to demonstrate the effectiveness of the developed converter and its control for these applications.