XINTC Electrolyser System – Technical Specifications
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Power & Control Module (PCM)
SPECIFICATIONS
| Power supply | DC power | Nominal 380 – 480 VDC Solar string MMPT target to busbar 430 – 440 VDC Open circuit voltage 190 VDC (minimum) – 550 VDC (maximum) |
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| AC power | Three-phase 400 VAC (+/- 10%), 50/60 Hz | ||
| Compartments | Power electronics | DC power only | No DC/DC rectifiers required. Solar panel strings directly connected to the DC busbar. Blocking diodes required on each solar panel string. |
| AC power only or AC + DC power | AC/DC rectifiers (300/400 kW each) based on adjustable IGBT technology with galvanic isolation, designed for the conversion of external AC voltage to internal DC voltage, with THDi below 5%. Includes power distribution station and MCCB. |
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| System control | Equipped with HMI touchscreen, 4G gateway for 24/7 remote monitoring, UPS, safety control systems, and comprehensive data logging. In the event of a critical incident, all safety systems remain active for a minimum of 24 hours. |
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| Enclosure | Shipping container | Customized and compartmentalized 20 ft high cube container, finished in RAL 7035 with C3 corrosion protection and external signage. Optional C5 coating. |
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| Gross Weight | < 10.500 kg (including 4x AC/DC rectifiers). | ||
| Accessibility | Power electronics | Accessible via 2x hinged doors at the end. | |
| System control | Accessible via a hinged door with panic opener on the longitudinal side (front). | ||
| Power consumption | Connection | Via existing cable entry on the longitudinal side (back). | |
| Standby | Hot/Cold standby ~ 0,5 kW | ||
| Safety | Shielding, emergency switches, warning lights, circuit breakers, temperature control, fuses, voltage control, air-tight cable entries, 24/7 remote monitoring. |
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| Ambient temperature and heat control | Standard | 5 °C to 35 °C. Forced air cooling by means of redundant mechanical ventilation. | |
| Optional | Up to 55 °C. Additional internal heat exchangers and external cooling medium. | ||
DC Power supply
Photovoltaic (PV) panels are directly connected to the Power Control Module (PCM) of the XINTC Electrolyser System, eliminating the need for MPPT optimizers, DC/AC or DC/DC converters, and battery storage systems. Each Gas Module pair features a custom-designed PCB and integrated control software, enabling real-time on/off switching in response to solar input fluctuations. As a result, the Gas Modules function as a Maximum Gas Production Tracker (MGPT), effectively replacing traditional MPPT systems. This innovative setup delivers a simpler, more efficient, and cost-effective system architecture.
Gas Production Module (GPM)
SPECIFICATIONS
| Gas production | Hydrogen | Purity 99.5 %. H2O < 5.000 ppm, O2 < 5.000 ppm. Outlet pressure 0.5 bar(g) |
| Oxygen | Internally diluted to safe concentrations before released to the atmosphere | |
| Gas Module | Input power | Nominal 5 kW. Peak power 6.5 kW |
| Weight | ~ 18 kg | |
| Working temperature | ~ 45 °C (55 °C maximum) | |
| Life expectancy | Designed for a service life of over 10 years (>87,500 operating hours), after which replacement of the Gas Modules may be required. |
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| Degradation | Degradation is less than 5% over 87,500 production hours at 100% load and 100,000 on/off cycles. With a full-service package, degradation remains below 2.5% under the same conditions. |
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| Section | Deploying 30 collaborating Gas Modules | 15 pair | |
| Input power | Nominal 150 kW. Peak power 200 kW, with solar or solar + DC. | |
| Production | Nominal 61,9 kg/24h. Peak power 78,1 kg/24h, with solar or solar + DC. | |
| Nominal 28,6 Nm3/h. Peak power 36,2 Nm3/h, with solar or solar + DC. | ||
| System | full container | Deploying 240 collaborating Gas Modules | 120 pair | |
| Power installed | Nominal 1.200 kW. Peak power 1.600 kW, with solar or solar + DC. | |
| Power factor solar DC | > 0,99. With solar DC coupling: no power thresholds, no curtailment losses. Installed system peak power MMPT equals installed power solar field. |
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| Production | Nominal 495 kg/24h. Peak power 625 kg/24h, with solar or solar + DC. | |
| Nominal 229,2 Nm3/h. Peak power 289,1 Nm3/h, with solar or solar + DC. | ||
| Operational dynamics | 1 – 100% dependent on system configuration | |
| Water supply | Specific water consumption ~ 10 l/kg, ~ 0,9 l/Nm3 | |
| Nominal potable water intake ~ 12 l/kg depending on water quality. | ||
| Potable water inlet pressure 2 – 6 bar(g) without softener, 3 - 6 bar(g) with softener. | ||
| Inlet conductivity <1,500 μS/cm, TDS < 1,000 mg/l, acidity < 0,1 meq/l | ||
| Inlet temperature 5-30 °C | ||
| Power consumption | Depending on system configuration, power source, load profile, ambient conditions, and operational dynamics, energy consumption ranges from 52.0 to 60.2 kWh/kg. |
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| Average specific power consumption | AC power at nominal load 57,75 kWh/kg at full system level. DC power at peak load 60,2 kWh/kg at full system level. |
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| Startup time | Hot startup time 0-100%: ~ 60 sec (electrolyte >35 °C) | |
| Cold startup time 0-100%: ~ 360 sec (ambient >5 °C) | ||
| Shutdown | 100-0%: ~ 10 sec. | |
| Turndown ratio | 120:1 maximum flow/minimum flow. | |
| Operational flexibility | 0-140 % with solar DC only or solar DC + AC, 0-100 % with AC-power only | |
| Enclosure | Shipping container | Customized 40 ft high cube container with liquid-tight floor, finished in RAL 7035 with C3 corrosion protection and external signage. Optional: C5 coating. |
| Gross weight | < 19.000 kg (with 8 sections installed) | |
| Compartment | Production compartment | Open interior layout with Gas Modules positioned on either side of a central walkway. Configurable from a minimum of 2 sections to a maximum of 8. Power is supplied via an axially hinged DC busbar. Auxiliary equipment, such as the RO unit, buffer tank, electrolyte unit, interchangeable filters, and gas treatment unit, is located at the accessible end of the container. |
| Accessibility | Accessible through two hinged doors at the end. | |
| Power consumption | Standby | Hot standby ~ 26–36 kW, including 16 kW for forced ventilation. |
| Cold standby ~ 26 kW. | ||
| Safety | Shielding, emergency switches, warning lights, circuit breakers, overpressure protection, temperature control, level control, fuses, voltage control, air-tight cable entries, hydrogen detection sensors, 24/7 remote monitoring. |
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| Noice level | < 85 dB(A) at 10 meters distance under full load conditions. | |
| Ambient temperature and heat control | Standard | 5 °C to 35 °C. Forced air cooling by means of redundant mechanical ventilation. |
| Optional | Up to 55 °C. Additional internal heat exchangers and external cooling medium. | |
Water treatment
The output of the RO-water treatment unit is 5μS/cm. With a 2-stage RO-unit we accept up to 1.000 TDS of input quality. The water installation is also equipped with an ion-exchange filter (softener) to remove Ca2+, Mg2+ (hardness ions) and also Cr2+ from the input. The drinking water may not contain dissolved chlorine gas Cl2 (but may contain chloride ions Cl-). It should therefore not be swimming pool quality because the Cl2 is an oxidizer (kills bacteria) but also damages the RO membranes. If this is the case, an additional active chlorine filter must be placed in the supply line to adsorb the chlorine gas.
Hydrogen Storage Module (HSM)
SPECIFICATIONS
| Membrane | Three-layer, double-sided PVC-coated polyester fabric with antistatic properties, low permeability, and resistance to UV, microbial growth, abrasion, and biogas. Flame retardant rated B1 in accordance with DIN 4102. |
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| Capacity | Various volumes: 150 m3, 400 m3, 1.000 m3 … 10.000 m3 | |
| Power supply | AC power | Three-phase 400 - 440 VAC, 50/60 Hz |
| Pressure | Inlet | 200 mbar maximum |
| Outlet | 200 mbar maximum | |
| Anchoring | Mechanical seal anchoring system, installed on concrete foundation using stainless steel flanges | |
| Power | Connection | Via control cabinet |
| System control & safety | H2 Gas Detector, weight sensor, volume level sensor, hydraulic gas safety valve, air overpressure valve, inspection window, air pressure transmitter, forced air cooling by means of redundant mechanical ATEX air vans. |
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| Ambient temperature | -20 °C to 55 °C | |
Compression & Purification Module (CPM)
SPECIFICATIONS
| Gas production | Hydrogen | At 210 Nm3/h, ISO 14687:2019 (99.97-99.99% H2) at 13 bar(g) outlet pressure. Impurities: <5 ppm O2, < 5 ppm H2O, < 300 ppm N2 |
| Power supply | AC power | Three-phase 400 V – 440 VAC, 50/60 Hz. 160 kW installed (peak) power |
| Compartments | Compression and purification compartment | Low maintenance two-stage Liquid Ring Compressor (LRC) skid, de-oxer unit (DEO) with water knock-out, proprietary PSA/TSA drying unit, output gas flow rate measurement, output gas purity measurement |
| System control compartment | Touch screen HMI, 4G gateway for remote monitoring, UPS, security monitoring, signaling and data logging. In case of a critical event the overall safety systems remain activated for at least 24 hours. |
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| Enclosure | Shipping container | Customized and compartmentalized 20 ft high cube container, finished in RAL 7035 with C3 corrosion protection and external signage. Optional: C5 coating. |
| Gross Weight | < 9.000 kg | |
| Accessibility | Compression and purification | Accessible through two hinged doors at both ends. |
| System control | Accessible via a hinged door with panic opener on the longitudinal (front) side. | |
| Power | Connection | Via existing cable entry on the longitudinal (rear) side. |
| Standby | Hot/cold standby (frost protection), ~ 3 kW in recycle mode. | |
| Consumption | ~ 4 kWh/kg at nominal load. | |
| Heat control | Forced air cooling by means of a speed-controlled mechanical ventilation system. | |
| Safety | Shielding, emergency switches, warning lights, circuit breakers, temperature control, fuses, voltage control, air-tight cable entries, 24/7 remote monitoring. |
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| Ambient temperature | Standard | -10 °C to 45 °C. Active chiller. |
| Optional | Up to 55 °C. Adjustment of the active chiller. | |
Battery Limits
PCM
| IN from | OUT to | Specifications | |
| DC (solar) power cables | SITE | 4x Entry Boxes, each: 16x N DC cables/Entry Box - Single core aluminum cable; 25 mm2, YMvK erx 16x P DC cables/Entry Box - Single core aluminum cable; 25 mm2, YMvK erx Each cable: ~550 Voc/~425 Vmp/ ~62,5 lmp |
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| AC power cables | SITE | 4x Entry Boxes, each: 3x AC cable, each 2x 3 Phase 400 VAC, 50 Hz, ~420 Imp, single core copper cables YMvK Flex 1x 120 mm2, Dca-s2/d2/a3, no shielding required, earth of Neutral required |
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| AC auxiliary power cable | SITE | 3-phase 400 VAC; 50 Hz; ~160 Imp; copper cable, PE, VG-YMvKas 4x 95 mm2 0,6/1 kV Dca-s2/d2/a3 |
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| Communication cable | SITE | Modbus RTU (RS485) | |
| Safety line | SITE | 24 VDC (yellow), multi core cable, n x 1,5 mm2 | |
| Safety line | SITE | 24 VDC (yellow), multi core cable, n x 1,5 mm2 | |
| Earthing | SITE | 2x at container corners, positioned diagonally opposite, connected to site grid, tinned solid copper rod, 50 mm2/OD8 mm |
Battery Limits
GPM
| IN from | OUT to | Specifications | |
| Water | SITE | OD16 mm - HDPE water pipe coupling with external 230 VAC, 50 Hz, 16 Amp power socket for water pipe heat tracing |
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| Drainage | SITE | Discharge to sewer (open sump) near the system module | |
| Process water | SITE | SITE | 1inch BSP thread |
| Earthing | SITE | Two grounding points located at diagonally opposite container corners, each connected to the site grid using a tinned solid copper rod (50 mm2 / Ø8 mm). |
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| Hydrogen gas | HSM | DN75 PN16 DIN-flange | |
| Nitrogen gas | SITE | 15 mm tube clamp fitting |
Battery Limits
HSM
| IN from | OUT to | Specifications | |
| Power cable | SITE | 3-phase 400 VAC; 50 Hz; ~16 Imp, copper cable, PE, VG-YMvKas 4X95 mm2 0,6/1kV Dca-s2/d2/a3 |
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| Safety line | SITE | 24 VDC (yellow), multi core cable, n x 1,5 mm2 | |
| Safety line | SITE | 24 VDC (yellow), multi core cable, n x 1,5 mm2 | |
| Communication cable | SITE | Modbus RTU (RS485) | |
| Hydrogen gas | GPM | DN100 PN16 DIN-flange | |
| Hydrogen gas | SITE/CPM | DN100 PN16 DIN-flange | |
| Earthing | Protecting earth |
Battery Limits
CPM
| IN from | OUT to | Specifications | |
| Power cable | SITE | 3-phase 400 VAC, 50 Hz; ~350 Imp; copper cable shielded + armored, VG-YMvKas 4X95 mm2 0,6/1 kV Dca-s2/d2/a3 |
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| Safety line | SITE | 24 VDC (yellow), multi core cable, n x 1,5 mm2 | |
| Safety line | SITE | 24 VDC (yellow), multi core cable, n x 1,5 mm2 | |
| Communication cable | SITE | Modbus RTU (RS485) | |
| Earthing | SITE | Two grounding points located at diagonally opposite container corners, each connected to the site grid using a tinned solid copper rod (50 mm2 / Ø8 mm). |
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| Hydrogen gas | HSM | DN100 PN16 DIN-flange | |
| Hydrogen gas | SITE | DN100 PN16 DIN-flange | |
| Nitrogen gas | SITE | 15 mm tube clamp fitting | |
| Drainage | SITE | Discharge to sewer (open sump) near the system module |
Installation Requirements
| Placement | The PCM and GPM units are installed in line with each other, maintaining a minimum clearance of 2 meters. All containerized units, PCM, GPM, and CPM, must be placed on a level concrete surface compliant with DIN 18202:2005, with sufficient load-bearing capacity. The installation site must be freely accessible for both a low-loader and a crane. |
| Utilities | Required utilities include a potable water supply with an inlet pressure of 2–6 bar(g), a sewage connection, and a 2 kW AC grid connection to power essential system components when the Electrolyser is not in operation. |
| Extra requirements | Based on the outcome of a formal risk assessment, the Environmental Service may mandate additional safety measures. These could include fencing around the Electrolyser installation, CCTV surveillance, or the construction of a concrete block partition wall. |
Technical Standards
| 2006/42/EC | Machinery Directive |
| 2014/30/EU | Electromagnetic Compatibility Directive |
| 2014/68/EU | Pressure Equipment Directive |
| 114/2014 + 153/99/92/EC | ATEX Directive |
| 2014/35/EC | Low Voltage Equipment |
| 2009/105/EC | Simple Pressure Vessels |
Considerations
Electrochemical Efficiency
- Electrochemical conversion within the gas modules is more efficient at lower power loads (i.e., lower current densities). Although higher loads result in greater hydrogen output, they are accompanied by a slight decrease in efficiency. Therefore, where operationally feasible, installing additional capacity and operating at reduced power levels may enhance overall system efficiency.
System Configuration
- Configuring the system with an even number of sections, rather than an odd number, can lead to cost savings, reduced material consumption, and improved energy conversion efficiency under standard operating conditions. Scenario-based calculations are recommended to support well-informed decisions and accurately evaluate the total cost of ownership.
