Pem Electrolyser Balance Of Plant Masterclass

Optimising Balance of Plant and Maximising Safety in PEM Electrolyzer Systems

What you'll learn

Describe what a PEM Electrolyser is and how it fits into the energy transition

Understand the operation and mechanical build up of the PEM Electrolyser Cell/ Stack

Name all parts of the Balance of Plant and understand the reason for each subsystem

Understand the basics of hydrogen safety in relation to the design of a PEM Electrolyser

Requirements

Prior knowledge is advantageous, but not mandatory.

Description

This in-depth technical course is designed for engineers and professionals working with PEM electrolyzers at scale. With rich real-world experience and a signature engaging delivery style, Hunor will take you beyond the textbook—into the lived complexity of green hydrogen production systems.You’ll explore:PEM stack operation: proton exchange dynamics, water crossover, and internal charge retentionBalance of Plant (BoP) engineering: ultrapure water systems (0.09 µS/cm), plate heat exchangers, adiabatic vs. refrigerant cooling, and desiccant dryers cycling hot/cold gasStack cell voltage monitoring, hydrogen-side pressure drop analysis, and safety interlocksHydrogen safety is a key focus. You’ll cover:The explosive window of 4%–75% H₂ in air, and why PEM electrolyzers are especially risky indoorsLEL-based detector calibration (%LEL ≠ %H₂) and shutdown thresholds across international codesHydrogen back-diffusion from 30 bar cathode to low-pressure anode—why minimum current density must be maintained to prevent flammable O₂-H₂ mixesReal-world failure case studies, including the Cureboard 2019 explosionA deep dive into electrical safety includes:Why isolated stacks remain lethal due to capacitor-like charge storageHow PEM stacks act like low-efficiency fuel cells when idle, recharging with ambient H₂/O₂How to use dischargers, lockout procedures, and continuous grounding to prevent fatal shocks—even days after shutdownFinally, you’ll examine the latest in stack durability innovation:Extra cathode-side cooling to prevent hotspots and membrane thinningLight anode pressurization to shrink O₂ bubble size and improve membrane hydrationModular, isolable stack arrays (e.g. Enapter's 420-stack Nexus and Omium’s redundancy approach) for serviceability and resilienceTrade-offs in catalyst loading and water purification cost-benefit at system scaleBy the end, you’ll understand how to safely run and optimize PEM electrolyzers in the field—balancing cost, safety, durability, and performance with confidence.

Overview

Section 1: Introduction

Lecture 1 Introduction

Lecture 2 Part 1

Lecture 3 Part 2

Lecture 4 Part 3

Lecture 5 Part 4

Beginner PEM Electrolyser engineers wanting a head start