Build a Solar Hydrogen
Fuel Cell System

The beginnings of solar hydrogen technology

Primary components

Gas processing and storage

Renewable energy sources and hybrid generating systems

Solar hydrogen versus solar battery systems

Time limits for battery storage

Hybrid energy storage systems

Types of solar cells

Electrical characteristics of solar cells

Elements of photovoltaic panel construction

Task specific photovoltaic modules

Basic components to build a solar panel

Designing the ESPM

Putting the cells into the frame

Attaching the power take off box

Placing the cover

Finish wiring the panel

Designing and setting up your system

Reducing circuit loss

Grounding

Diodes

Switches

Data loggers

Fuses, connectors and cables

Positioning solar panels

Solar trackers

Mounting PV panels

Final design considerations

Solid electrolyte PEM vs. alkaline

Electrolyzer basics

Porous alloy electrodes

Prepared surface flat plate electrodes

Mesh electrodes

Electrode spacing

The electrolyte

Potassium hydroxide (KOH) solution strength

Safety

Water for the electrolyzer

Solar water distillation

The P41 electrolyzer

Design for renewable energy power sources

Making intermittent power efficient

Electrode materials

Thermal flywheel

Supercapacitors

Micro and macro electrode surface considerations

Raney metal surfaces

Electrode shape

Hydrostatic pressure

Building the P41 Electrolyzer

Tool list

Materials list

Building the P41

Electrolyzer tank

Positive electrode assembly ports

Gas exit port cap preparation

Separator preparation

Positive electrode assembly preparation

Washers

Slip out the screw and the mesh cylinder

The installed positive electrode connectors

Negative electrode assembly preparation

Preparing the bottom cap

Installing electrolyte entry head/negative electrode assembly

Installing gas port exit cylinder head and gas separator

Hydrostatic testing

Power supply connections

Testing the electrolyzer with KOH

Setting up the electrolyzer

Electrolyte reservoir

Set up the exit port tubes

Connect to the power source

Fill the electrolyzer

As you like it

Quick comparisons

BSPMs and electrolyzers

Series connected electrolyzers

Setting up electrolyzer banks

Parallel connected electrolyzers

Stand alone configuration

Large electrolyzers vs. small electrolyzer banks

Designing your own electrolyzers

Electrolyzer performance testing

Collect performance data for RE power sources

Testing equipment

Measuring gas output

Gas production formulas

Hydrogen history and characteristics

Hydrogen safety

Grounding

Hydrogen proof seals

Restrict access to the hydrogen area

Make electrical devices hydrogen safe

Hydrogen compared to other fuels

Hydrogen in the presence of oxygen

Oxygen

Oxygen and safety

Generated or ambient oxygen?

Moisture and fuel cells

Removing contaminants

Scrubbers and diffusers

Filters and coalescers

Recombiners

Check valves and regulators

Environment of operation

System longevity

Gas processing system

Gas scrubber

Vinegar and distilled water

Experiment with different designs

Making bubblers

Tool list

Materials list for 2 bubblers

Other parts for gas processing system

Making a bubbler

Assembly

Connecting the valves and tubing

Mounting the system

Component configuration

Additions to the system

Gas detection system

Catalytic recombiners

Safety considerations for recombiners

Building a recombiner

Purging option

Pressure gauges, indicators, and switches

Component upgrading

Gas storage

Liquid phase storage

Hydride storage

Metal organic frameworks

Low tech alternatives

Double drum storage

Floating tank storage

Calculating tank capacity

Adding pressure

Safe storage

Setup and check the system

Fuel cell basics

Types of fuel cells

PEM fuel cell configurations

Planar fuel cell stacks

Build the L79 planar fuel cell stack

Tool list

Materials list

Constructing the L79

Selecting the materials for the electrode/gas flow field

Preparing the electrodes for template transfer

Transferring the templates

Etching the board

Remove the resist

Routing the flow fields

Using a drill press or milling machine

Setting up for milling

Controlling the depth

Smooth the edges and clean the plates

Materials for plating the circuit

Brush plating

Plating kits

Tinning the series edge connectors

Preparing the tab connects

Making the electrode gasket

Making the surrounds

Inserting the membranes

Attach the gas supply gasket

Preparing the end plate

Aligning the plates

Soldering the series connections and power takeoff tabs

Preparing the pressure braces

Installing the gas port connectors

Final Assembly

Prepare the stack for testing

Purging the stack

Testing the fuel cell stack

Trouble shooting

Fuel cell power supplies

Output configurations

Running the stacks