Experimental integration of a foam-based floating photovoltaic (floatovoltaic) system with an anion exchange membrane electrolyzer for 5 kW-Scale green hydrogen production

Strategically scheduling electrolyzers to harness surplus solar photovoltaic (PV) energy decreases reliance on the grid and enhances overall system efficiency. This study experimentally evaluates a 7-kW foam-based FPV integrated with a 27-cell anion exchange membrane (AEM) electrolyzer to assess feasibility under off-grid conditions. The methodology involved assembling the FPV modules on a pond, powering the AEM stack via three 2.5 kW inverters and MPPT charge controllers, and recording operational data such as voltage, current, temperature, and gas flow; using a Cerbo-GX monitor, multimeters, rotameters, and liquid-displacement timing. Key findings include a stack-level energy conversion efficiency of 73.3–86.2 % (high heating value basis), a minimum specific energy consumption of 45.77 kWh/kg H 2 , and hydrogen purity of 99.22 %. System-level electrical efficiency ranged from 66 % to 71 %, with power conversion losses identified at the inverter and power-supply stages. Simulation of electrolyzer scheduled operation only upon surplus PV generation showed improved energy utilization. These results demonstrate the viability of FPV-AEM coupling for decentralized green hydrogen production and highlight the potential for direct DC coupling and enhanced thermal management to further reduce energy losses in future implementations. • AEM electrolyzers operate efficiently with battery-backed floating solar PV systems. • External heating and proper insulation can improve overall system efficiency. • Solar-powered AEM electrolyzers can achieve an HHV specific energy of 45.77 kWh/kg. • Direct solar PV DC powering with no inverter can halve AEM electrolyzer energy losses. • Hydrogen appears as a promising energy storage solution in off-grid solar PV systems.