HIL Based Hydrogen Generation Converter Parameters Optimization Methodology

Hydrogen generation has increased in recent years due to the rise of intermittent renewable sources such as wind and photovoltaic energy. The need for efficient energy storage makes hydrogen an attractive option due to its high energy density and eco-friendly characteristics, as well as the growing adoption of hydrogen-based electric vehicles. This paper presents a methodology for optimizing the bus voltage and switching frequency of a hydrogen generation converter, consisting of a diode bridge rectifier followed by an interleaved buck converter. Using real electrolyzer stack data and a topology aligned with grid requirements, the study provides a converter's evaluation for bus voltage and switching frequency optimization. The methodol-ogy leverages hardware-in-the-loop (HIL) tools for power quality and loss analysis, along with open-source design tools, offering a comprehensive approach to improving hydrogen generation performance. The results highlight the potential benefits of using SiC components to increase the switching frequency and adjust the DC bus voltage to achieve a better compromise between efficiency and performance. The optimal operating point was identified with a switching frequency between 12 kHz and 15 kHz and an input RMS voltage of 260 V, which was the most effective configuration for a 150 kW, 24-pulse electrolyzer system. This setup enables the system to reach an average efficiency >97% throughout the electrolyzer lifecycle, demonstrating the viability of the proposed optimization methodology for real-world hydrogen generation applications.