WO2023229879A1

WO2023229879A1 - Control systems and methods for monitoring electrolyzer cell stack conditions and extending operational life

Info

Publication number: WO2023229879A1
Application number: PCT/US2023/022373
Authority: WO
Inventors: Dustin VICKRESS; Anson Sinanan; Richard J. Ancimer; Nathaniel Ian Joos
Original assignee: Cummins Inc.; Hydrogenics Corporation
Priority date: 2022-05-27
Filing date: 2023-05-16
Publication date: 2023-11-30

Abstract

A method of optimizing operating lifespan of an electrolysis system includes measuring an operating parameter of a component of the system at a first location of the electrolysis system with a first sensor to obtain a raw measurement, the raw measurement including a value and/or a rate of change of the parameter, receiving the raw measurement at a controller, comparing the value to a nominal measurement and/or the rate of change to a nominal rate of change. The method further includes diagnosing an abnormality of the component based on the value and/or rate of change differing from nominal values. The method further includes, in response to the diagnosis of the abnormality, outputting a message to an operator of the electrolysis system indicative of the abnormality.

Description

CONTROL SYSTEMS AND METHODS FOR MONITORING ELECTROLYZER

CELL STACK CONDITIONS AND EXTENDING OPERATIONAL LIFE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This nonprovisional application claims the benefit and priority, under 35 U.S.C. § 119(e) and any other applicable laws or statutes, to U.S. Provisional Application Serial No. 63/346,640 filed on May 27, 2022, the entire disclosure of which is hereby expressly incorporated herein by reference.

TECHNICAL FIELD

[0002] The present disclosure generally relates to electrolysis systems, in particular control systems and methods for monitoring conditions of electrolyzer cell stacks in an electrolysis system.

BACKGROUND

[0003] In electrolysis systems, degradation of the electrolyzer cell stacks may occur, causing reduced potential lifespan of the stacks. For example, excessive amounts of voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, and gas humidity may lead to damage of the electrolyzer cell stacks, thus reducing their lifespan. As such, monitoring of various operating parameters of the system is useful for maximizing the lifespan of the electrolyzer cell stacks. Typical monitoring of various operating parameters inside a cell stack as well as within the system as a whole remains difficult and invasive to confirm directly (e.g. without disassembly and inspection). Accordingly, it would be advantageous to provide a minimally invasive system of monitoring system performance, diagnosing system problems, and predicting a lifespan of electrolyzer cell stacks.

[0004] The present disclosure is directed to systems and methods for monitoring electrolysis system conditions and extending operational life of the electrolysis system. In particular, the present disclosure utilizes raw measurement sensors, soft sensors, and historical data to diagnosis abnormal behavior and predict life of the electrolysis system components. The use of soft sensors and historical data at various locations within the system for such diagnoses and predictions eliminates the need for additional sensors and measuring devices within the system, and also leverages existing reliable sensing technologies in obtaining empirical data for analysis. Thus, the systems and methods described herein allow for lifespan extension while minimizing invasiveness, as well as eliminating the need to disassemble and inspect certain components of the system. SUMMARY

[0005] According to the present disclosure, a method of monitoring at least one operating parameter in an electrolysis system for optimizing the operating lifespan of at least one component of the electrolysis system is disclosed. The method includes measuring the at least one operating parameter at a first location of the electrolysis system with a first sensor to obtain a first raw measurement of the at least one operating parameter, the first raw measurement including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter, and receiving, at a controller, the first raw measurement, the controller including at least one computer-readable storage medium.

[0006] In some embodiments, the method further includes comparing, via the controller, at least one of (i) the first value of the first raw measurement to a predetermined nominal measurement or (ii) the first rate of change of the first raw measurement to a predetermined nominal rate of change, diagnosing, via the controller, at least one abnormality of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differing from the predetermined nominal measurement by a first amount or (ii) the first rate of change of the first raw measurement differing from the predetermined nominal rate of change by a first rate amount, and, in response to the diagnosis of the at least one abnormality, outputting a first message, via the controller, to an operator of the electrolysis system indicative of the at least one abnormality.

[0007] In some embodiments, the method further includes determining, via the controller, a predicted lifespan of the at least one component including a predicted length of lifespan based on the first raw measurement, comparing, via the controller, the predicted length of lifespan with a predetermined length of lifespan of the at least one component, and, in response to the predetermined length of lifespan being different than the predicted length of lifespan by a first amount of time, outputting a second message, via the controller, to the operator of the electrolysis system indicative of the predicted lifespan.

[0008] In some embodiments, the method further includes calculating, via the controller, a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different than the first location, the first calculated measurement including at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of the at least one abnormality is further based on at least one of (i) the first calculated value of the first calculated measurement differing from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differing by a first calculated rate amount. The determining, via the controller, of the predicted lifespan of the at least one component including the predicted length of lifespan is based on at least one of the first raw measurement and the first calculated measurement.

[0009] In some embodiments, the method further includes, in response to the predetermined length of time differing from the predicted length of lifespan by a second amount of time that is greater than the first amount of time, shutting down the electrolysis system.

[0010] In some embodiments, the diagnosis of the at least one abnormality is further based on the at least one of a total age of the electrolysis system, a total amount of hydrogen already produced by the electrolysis system, or a present operating condition of the electrolysis system.

[0011] In some embodiments, the at least one operating parameter includes at least one of voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, or gas humidity, and the at least one component includes at least one of an electrolyzer cell stack, a pump, a heat exchanger, a tank, or a valve of the electrolysis system.

[0012] In some embodiments, the method further includes receiving, at the controller, at least one historical measurement of the at least one operating parameter at the first location of the electrolysis system that was measured by the first sensor prior to the first raw measurement, and calculating, via the controller, a second calculated measurement of the at least one operating parameter at the second location based at least in part on the first raw measurement and the at least one historical measurement.

[0013] In some embodiments, the diagnosis of the at least one abnormality is further based on the at least one historical measurement differing from the predetermined nominal measurement by a third amount, and the determining of the predicted lifespan is further based on the first raw measurement, the first calculated measurement, the at least one historical measurement, and the second calculated measurement.

[0014] In some embodiments, the method further includes measuring the at least one operating parameter at a plurality of additional first locations of the electrolysis system different than the first location with a plurality of additional sensors to obtain an additional raw measurement of the at least one operating parameter at each additional location of the plurality of additional locations to establish a plurality of additional raw measurements, and receiving, at the controller, the plurality of additional raw measurements. The method may further include calculating, via the controller, a plurality of additional calculated measurements of the at least one operating parameter at respective additional second locations of the electrolysis system different than the first location, the plurality of additional first locations, and the additional second locations based at least in part on the plurality of additional raw measurements, and determining, via the controller, the predicted lifespan of the electrolyzer cell stack based on the first raw measurement, the first calculated measurement, the at least one historical measurement, the second calculated measurement, the plurality of additional raw measurements, and the plurality of additional calculated measurements.

[0015] An electrolysis system according to a further aspect of the present disclosure includes at least one component including at least one of a pump, a heat exchanger, a tank, or a valve, an electrolyzer cell stack configured to separate input water into hydrogen and oxygen, a controller including at least one computer-readable storage medium, and a first sensor. The first sensor is operably connected to the controller and configured to measure at least one operating parameter at a first location of the electrolysis system to obtain a first raw measurement of the at least one operating parameter, the first raw measurement including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter.

[0016] In some embodiments, the controller is configured to compare at least one of (i) the first value of the first raw measurement to a predetermined nominal measurement or (ii) the first rate of change of the first raw measurement to a predetermined nominal rate of change, diagnose at least one abnormality of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differing from the predetermined nominal measurement by a first amount or (ii) the first rate of change of the first raw measurement differing from the predetermined nominal rate of change by a first rate amount, and, in response to the diagnosis of the at least one abnormality, output a first message, via the controller, to an operator of the electrolysis system indicative of the at least one abnormality.

[0017] In some embodiments, the controller is further configured to determine a predicted lifespan of the at least one component including a predicted length of lifespan based on the first raw measurement, compare, the predicted length of lifespan with a predetermined length of lifespan of the at least one component, and, in response to the predetermined length of lifespan being different than the predicted length of lifespan by a first amount of time, output a second message to the operator of the electrolysis system indicative of the predicted lifespan.

|0018| In some embodiments, the electrolysis system further includes a first soft sensor configured to calculate a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different than the first location, the first calculated measurement including at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of the at least one abnormality via the controller is further based on at least one of (i) the first calculated value of the first calculated measurement differing from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differing by a first calculated rate amount. The determining of the predicted lifespan of the at least one component via the controller including the predicted length of lifespan is based on at least one of the first raw measurement and the first calculated measurement.

[0019] In some embodiments, the at least one operating parameter includes an amount of conductivity of water flowing through the electrolysis system, and the amount of conductivity of the water is inversely proportional to the predicted lifespan of the electrolyzer cell stack.

[0020] In some embodiments, the amount of conductivity of the water is determined based on an ion concentration of the water.

[0021] In some embodiments, the ion concentration of the water includes measurements of a concentration of at least one of fluorine, platinum, iron, calcium, chromium, and nickel.

[0022] In some embodiments, the first location of the electrolysis system is located downstream of the electrolyzer stack and the second location of the electrolysis system is located downstream of the first location in the electrolyzer system.

[0023] In some embodiments, the electrolysis system further includes a hydrogen separator located downstream of and fluidically connected to the electrolyzer stack of the electrolysis system, a polishing loop fluidically connected to the hydrogen separator and configured to treat drain flow from the hydrogen separator for recirculation into an oxygen separator, the oxygen separator located downstream of and fluidically connected to the electrolyzer stack and downstream of and fluidically connected to the polishing loop, and a water circulation pump located downstream of and fluidically connected to the oxygen separator and configured to direct water from the oxygen separator to an input of the electrolyzer stack.

[0024] In some embodiments, the first location of the electrolysis system is located along a first fluidic line that extends between and interconnects the polishing loop and the oxygen separator, and the second location of the electrolysis system is located along a second fluidic line that extends between and interconnects the water circulation pump and the input of the electrolyzer.

|0025 | In some embodiments, the electrolysis system further includes a second, third, and fourth sensor arranged within the polishing loop and each operably connected to the controller, each of the second, third, and fourth sensors being configured to measure the water conductivity at a third, fourth, and fifth location within the polishing loop, respectively, the second, third, and fourth sensors being configured to obtain second, third, and fourth raw measurements of the water conductivity, respectively, and send the second, third, and fourth raw measurements to the controller.

[0026] The electrolysis system may further include a second soft sensor configured for calculations regarding a sixth location directly downstream of the hydrogen separator, a third soft sensor configured for calculations regarding a seventh location directly upstream of the oxygen separator, and a fourth soft sensor configured for calculations regarding an eighth location along a third fluidic line that extends from the water circulation pump to the polishing loop, each of the second, third, and fourth soft sensors being configured to calculate second, third, and fourth calculated measurements of the water conductivity at the sixth, seventh, and eighth locations, respectively, based at least in part on the first, second, third, and fourth raw measurements. The controller is further configured to determine the predicted lifespan of the at least one component including the predicted length of lifespan based on the first, second, third, and fourth raw measurements and the first, second, third, and fourth calculated measurements.

[0027] In some embodiments, the diagnosis of the at least one abnormality is further based on the at least one of a total age of the electrolysis system, a total amount of hydrogen already produced by the electrolysis system, or a present operating condition of the electrolysis system.

BRIEF DESCRIPTION OF DRAWINGS

[0028] This disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0029] FIG. 1A is a perspective view of an electrolyzer stack according to the present disclosure;

[0030] FIG. IB is a schematic view of an electrolysis system configured to utilize the electrolyzer cells stack of FIG. 1 A;

[0031 ] FIG. 1 C is a schematic view of an additional portion of the electrolysis system of FIG.

IB;

[0032] FIG. 2 is a schematic view of a control system, according to one embodiment of the present disclosure, for monitoring at least one operating parameter in the electrolysis system for forecasting a lifespan of the electrolyzer cell stack of the electrolysis system of FIGS. 1A-1C;

[0033] FIG. 3 is a schematic view of a monitoring system of the control system of FIG. 2, showing that the monitoring system is for an electrolysis fluidic circuit having two electrolyzer cell stacks;

[0034] FIG. 4 is a schematic view of the various monitoring locations of the monitoring system for the electrolysis fluidic circuit of FIG. 3 ;

[0035] FIG. 5 is a schematic view of a polishing loop of the electrolysis fluidic circuit of FIGS. 3 and 4; and

[0036] FIG. 6 is a flow chart of a method of monitoring at least one operating parameter in an electrolysis system according to a further aspect of the present disclosure, the method including forecasting lifespan of an electrolyzer cell stack of the electrolysis system. DETAILED DESCRIPTION

[0037] Electrochemical cells and electrolytic cells provide chemical reactions that include electricity. For example, a fuel cell uses hydrogen and oxygen to produce electricity. An electrolyzer uses water and electricity to produce hydrogen and oxygen.

[0038] An electrolyzer comprises one or more electrolytic cells that utilize electricity to chemically produce substantially pure hydrogen and oxygen from water. Often the electrical source for the electrolyzer is produced from power or energy generation systems, including renewable energy systems such as wind, solar, hydroelectric, and geothermal sources for the production of green hydrogen. In turn, the pure hydrogen produced by the electrolyzer is often utilized as a fuel or energy source for those same power generation systems, such as fuel cell systems.

[0039] The typical electrolytic cell, also referred to as an “electrolyzer cell,’’ is comprised of many assemblies compressed and bound into a stack. An electrolytic cell includes a multicomponent membrane electrode assembly (MEA) that has an anode, a cathode, and an electrolyte. Typically, the anode, cathode, and electrolyte of the membrane electrode assembly (MEA) are configured in a multi-layer arrangement that enables the electrochemical reaction to produce hydrogen via contact with one or more gas diffusion layers. A gas diffusion layer (GDL) and/or a porous transport layer (PTL) is typically located on one or both sides of the MEA. Bipolar plates (BPP) often reside on either side of the GDLs and separate the individual electrolytic cells of the stack from one another.

[0040] The present disclosure is directed to systems, assemblies, and methods used to predict and optimize the lifespan of electrolyzer cells and/or stacks in an electrolysis system 200. The present systems and methods include utilizing raw measurements, soft sensors, and historical data to predict the lifespans of the electrolyzer cells and/or stacks. According to a first aspect of the present disclosure as shown in FIG. 2, a control system 100 for monitoring (“a control system’’) at least one operating parameter 104 in an electrolysis system 200 is shown. The at least one operating parameter may be for forecasting a lifespan of an electrolyzer cell stack 204, 208 of the electrolysis system 200 (see FIG. 3). A person skilled in the art will understand that the electrolysis system 200 of the first aspect of the present disclosure, as shown in FIGS. 2-5, may be configured similarly to the exemplary electrolysis system 10 shown in FIGS. 1A-1C and described below, or may include additional or fewer components as necessitated by the design requirements of the electrolysis system 200.

[0041] As shown in FIGS. 1A and IB, electrolysis systems 10 are typically configured to utilize water and electricity to produce hydrogen and oxygen. An electrolysis systems 10 typically includes one or more electrolyzer cells 80 that utilize electricity to chemically produce substantially pure hydrogen 13 and oxygen 15 from deionized water 30. Often the electrical source for the electrolysis systems 10 is produced from power or energy generation systems, including renewable energy systems such as wind, solar, hydroelectric, and geothermal sources for the production of green hydrogen. In turn, the pure hydrogen produced by the electrolysis systems 10 is often utilized as a fuel or energy source for those same power generation systems, such as fuel cell systems. Alternatively, the pure hydrogen produced by the electrolysis systems 10 may be stored for later use.

[0042] The typical electrolyzer cell 80, or electrolytic cell, is comprised of multiple assemblies compressed and bound into a single assembly, and multiple electrolyzer cells 80 may be stacked relative to each other, along with bipolar plates (BPP) 84, 85 therebetween, to form an electrolyzer cell stack (for example, electrolyzer cell stacks 11, 12 in FIG. IB). Each electrolyzer cell stack 11, 12 may house a plurality of electrolyzer cells 80 connected together in series and/or in parallel. The number of electrolyzer cell stack 11, 12 in the electrolysis systems 10 can vary depending on the amount of power required to meet the power need of any load (e.g., fuel cell stack). The number of electrolyzer cells 80 in an electrolyzer cell stack 11, 12 can vary depending on the amount of power required to operate the electrolysis systems 10 including the electrolyzer cell stack 11, 12.

[0043] An electrolyzer cell 80 includes a multi-component membrane electrode assembly (MEA) 81 that has an electrolyte 8 IE, an anode 81 A, and a cathode 81C. Typically, the anode 81A, cathode 81C, and electrolyte 81E of the membrane electrode assembly (MEA) 81 are configured in a multi-layer arrangement that enables the electrochemical reaction to produce hydrogen and/or oxygen via contact of the water with one or more gas diffusion layers 82, 83. The gas diffusion layers (GDL) 82, 83, which may also be referred to as porous transport layers (PTL), are typically located on one or both sides of the MEA 81. Bipolar plates (BPP) 84, 85 often reside on either side of the GDLs and separate the individual electrolyzer cells 80 of the electrolyzer cell stack 11, 12 from one another. One bipolar plate 85 and the adjacent gas diffusion layers 82, 83 and MEA 81 can form a repeating unit 88.

[0044] As shown in FIGS. IB and 1C, an exemplary electrolysis system 10 can include two electrolyzer cell stacks 11, 12 and a fluidic circuit 10FC including the various fluidic pathways shown in FIGS. IB and 1C that is configured to circulate, inject, and purge fluid and other components to and from the electrolysis systems 10. A person skilled in the art would understand that one or a variety of a number of components within the fluidic circuit 10FC, as well as more or less than two electrolyzer cell stacks 11, 12, may be utilized in the electrolysis systems 10. For example, the electrolysis systems 10 may include one electrolyzer cell stack 11, and in other examples, the electrolysis systems 10 may include three or more electrolyzer cell stacks. [0045] The electrolysis systems 10 may include one or more types of electrolyzer cell stacks 11, 12 therein. In an illustrative illustrated embodiment, a polymer electrolyte membrane (PEM) electrolyzer cell 80 may be utilized in the stacks 11, 12. A PEM electrolyzer cell 80 typically operates at about 4°C to about 150°C, including any specific or range of temperatures comprised therein. A PEM electrolyzer cell 80 also typically functions at about 100 bar or less, but can go up to about 1000 bar (including any specific or range of pressures comprised therein), which reduces the total energy demand of the system. A standard electrochemical reaction that occurs in a PEM electrolyzer cell 80 to produce hydrogen is as follows.

• Anode: 2H₂O O₂ + 4H⁺ + 4e~

• Cathode: 4H⁺ + 4e" 2H₂

• Overall: 2H₂O (liquid) 2H₂ + O₂

[0046] Additionally, a solid oxide electrolyzer cell 80 may be utilized in the electrolysis systems 10. A solid oxide electrolyzer cell 80 will function at about 500°C to about 1000°C, including any specific or range of temperatures comprised therein. A standard electrochemical reaction that occurs in a solid oxide electrolyzer cell 80 to produce hydrogen is as follows.

• Anode: 2O^2- — > O₂ + 4e^_

• Cathode: 2H₂O 4e + 2H₂ + 2O²'

• Overall: 2H₂O (liquid) 2H₂ + O₂

[0047] Moreover, an AEM electrolyzer cell 80 may utilized, which uses an alkaline media. An exemplary AEM electrolyzer cell 80 is an alkaline electrolyzer cell 80. Alkaline electrolyzer cells 80 comprise aqueous solutions, such as potassium hydroxide (KOH) and/or sodium hydroxide (NaOH), as the electrolyte. Alkaline electrolyzer cells 80 typically perform at operating temperatures ranging from about 0°C to about 150°C, including any specific or range of temperatures comprised therein. Alkaline electrolyzer cell 80 generally operate at pressures ranging from about 1 bar to about 100 bar, including any specific or range of pressures comprised therein. A typical hydrogen-generating electrochemical reaction that occurs in an alkaline electrolyzer cell 80 is as follows.

• Anode: 4OH" — >■ O₂ + 2H₂O + 4e^_

• Cathode: 4H₂O + 4e" 2H₂ + 4OH'

• Overall: 2 H₂O 2H₂ + O₂

[0048] As shown in FIG. IB, the electrolyzer cell stacks 11, 12 include one or more electrolyzer cells 80 that utilize electricity to chemically produce substantially pure hydrogen and oxygen from water. In turn, the pure hydrogen produced by the electrolyzer may be utilized as a fuel or energy source. As shown in FIG. IB, the electrolyzer cell stack 11, 12 outputs the produced hydrogen along a fluidic connecting line 13 to a hydrogen separator 16, and also outputs the produced oxygen along a fluidic connecting line 15 to an oxygen separator 14.

[0049] The hydrogen separator 16 may be configured to output pure hydrogen gas and also send additional output fluid to a hydrogen drain tank 20, which then outputs fluid to a deionized water drain 21 . The oxygen separator 14 may output fluid to an oxygen drain tank 24, which in turn outputs fluid to a deionized water drain 25. A person skilled in the art would understand that certain inputs and outputs of fluid may be pure water or other fluids such as coolant or byproducts of the chemical reactions of the electrolyzer cell stacks 11, 12. For example, oxygen and hydrogen may flow away from the cell stacks 11, 12 to the respective separators 14, 16. The system 10 may further include a rectifier 32 configured to convert electricity 33 flowing to the cell stacks 11, 12 from alternating current (AC) to direct current (DC).

[0050] The deionized water drains 21, 25 each output to a deionized water tank 40, which is part of a polishing loop 36 of the fluidic circuit 10FC, as shown in FIG. 1C. Water with ion content can damage electrolyzer cell stacks 11, 12 when the ionized water interacts with internal components of the electrolyzer cell stacks 11, 12. The polishing loop 36, shown in greater detail in FIG. 1C, is configured to deionize the water such that it may be utilized in the cell stacks 11 , 12 and not damage the cell stacks 11, 12.

[0051 ] In an illustrative embodiment, the deionized water tank 40 outputs fluid, in particular water, to a deionized water polishing pump 144. The deionized water polishing pump 144 in turn outputs the water to a water polishing heat exchanger 46 for polishing and treatment. The water then flows to a deionized water resin tank 48.

[0052] Coolant is directed through the electrolysis systems 10, in particular through a deionized water heat exchanger 72 that is fluidically connected to the oxygen separator 14. The coolant used to cool said water may also be subsequently fed to the water polishing heat exchanger 46 via a coolant input 27 for polishing. The coolant is then output back to the deionized water heat exchanger 72 for cooling the water therein.

[0053] After the water is output from the deionized water polishing heat exchanger 46 and subsequently to the deionized water resin tank 48, a portion of the water may be fed to deionized water high pressure feed pumps 60. Another portion of the water may be fed to a deionized water pressure control valve 52, as shown in FIG. 1C. The portion of the water that is fed to the deionized water pressure control valve 52 flows through a recirculation fluidic connection 54 that allows the water to flow back to the deionized water tank 40 for continued polishing.

[0054] In some embodiments, the electrolysis systems 10 may increase deionized water skid for polishing water flow to flush out ions within the water at a faster rate. The portion of the water that is fed to the deionized water high pressure feed pumps 60 is then output to a deionized water feed 64, which then flows into the oxygen separator 14 for recirculation and eventual reuse in the electrolyzer cell stacks 11, 12. This process may then continuously repeat.

[0055] The electrolysis systems 10 described herein, may be used in stationary and/or immovable power system, such as industrial applications and power generation plants. The electrolysis systems 10 may also be implemented in conjunction with other electrolysis systems 10.

[0056] The present electrolysis systems 10 may be comprised in stationary or mobile applications. The electrolysis systems 10 may be in a vehicle or a powertrain 400. A vehicle or powertrain 400 comprising the electrolysis systems 10 may be an automobile, a pass car, a bus, a truck, a train, a locomotive, an aircraft, a light duty vehicle, a medium duty vehicle, or a heavy duty vehicle.

[0057] In addition, it may be appreciated by a person of ordinary skill in the art that the electrolysis system 10, electrolyzer stack 11, 12, and/or the electrolyzer cell 80 described in the present disclosure may be substituted for any electrochemical system, such as a fuel cell system, a fuel cell stack, and/or a fuel cell (FC), respectively. As such, in some embodiments, the features and aspects described and taught in the present disclosure regarding electrolysis system 10, electrolyzer stack 11, 12, and/or the electrolyzer cell 80 also relate a fuel cell system, a fuel cell stack, and/or a fuel cell (FC), respectively. In further embodiments, the features and aspects described or taught in the present disclosure do not relate, and are therefore distinguishable from, those of a fuel cell system, a fuel cell stack, and/or a fuel cell (FC).

[0058] As shown in FIG. 2, the control system 100 includes a controller 110 configured to perform various calculations as described herein. The controller 110 is also configured to facilitate communications of the control system 100 via a communications network 116. The controller 110 is capable of controlling operational functionality of various components of the system 100 and other equipment and/or parts included therein and in the electrolysis system 200. |0059| The control system 100 further includes a monitoring system 130 configured to monitor various parameters 104 of the electrolysis system 200 and to communicate these parameters 104 to the controller 110, as shown in FIG. 2. The controller 110 utilizes the parameters 104 of the electrolysis system 200 that are measured and/or calculated by the monitoring system 130. The controller 110 further utilizes historical data 108 of these parameters 104. The parameters 104 may be utilized to diagnose abnormal behavior occurring in various system components.

[0060] The parameters 104 may also be used to feed a predictive model 120, which may be embodied within the processor 112 of the controller 110, to determine a potential lifespan of at least one of the electrolyzer cell stacks 204, 208 of the electrolysis system 200, as shown in FIGS. 2 and 3. The controller 110 then outputs to an operator 190 of the system 200 what the abnormal behavior is and how to remedy the behavior, as well as outputting whether the predicted lifespan is lowered too far beyond a predetermined acceptable lifespan of the cell stacks 204, 208.

[0061] In an illustrative embodiment, as shown in FIG. 2, the controller 110 includes a memory 1 1 1 , and a processor 1 12. The memory 1 1 1 and processor 112 are in communication with each other. The processor 112 may be embodied as any type of computational processing tool or equipment capable of performing the functions described herein. For example, the processor 112 may be embodied as a single or multi-core processor(s), digital signal processor, microcontroller, or other processor or processing/controlling circuit.

[0062] The memory 111 may be embodied as any type of volatile or non-volatile memory or data storage capable of performing the functions described herein. Moreover, the controller 110 may also include additional or alternative components, such as those commonly found in a computer (e.g., various input/output devices, resistors, capacitors, etc.). In other embodiments, one or more of the illustrative controllers 110 of components may be incorporated in, or otherwise form a portion of, another component. For example, the memory 111, or portions thereof, may be incorporated in the processor 112.

[0063] In operation, the memory Ti l may store various data and software used during operation of the controller 110 such as operating systems, applications, programs, libraries, and drivers. The memory 111 is communicatively coupled to the processor 112 via an I/O subsystem, which may be embodied as circuitry and/or components to facilitate input/output operations with the processor 112, the memory 111, and other components of the controller 110. In one embodiment, the memory 111 may be directly coupled to the processor 112, for example via an integrated memory controller hub. Additionally, in some embodiments, the I/O subsystem may form a portion of a system-on-a-chip (SoC) and be incorporated, along with the processor 112, the memory 111, and/or other components of the controller 110, on a single integrated circuit chip (not shown).

[0064] The components of the communication network 116 may be configured to use any one or more communication technologies (e.g., wired, wireless and/or power line communications) and associated protocols (e.g., Ethernet, InfiniBand®, Bluetooth®, Wi-Fi®, WiMAX, 3G, 4G LTE, 5G, etc.) to effect such communication among and between system components and devices, including but not limited to between the monitoring system 130, the control system 110, and/or the operator 190. Moreover, the historical data 108 may be stored within the memory 111 of the controller 110 or may be stored on a separate storage device 113 that is communicatively connected to the controller 110 via the communication network 116. [0065] Similarly, the predictive model 112 may be stored within the memory 111 and/or processor 112 of the controller 110. Alternatively, the predictive model 112 may also be stored on a separate storage device 113, and/or executed on a separate controller (not shown), communicatively connected to the controller 110 via the communication network 116. Moreover, diagnostic information, including nominal values, rates, and behaviors, as well as solutions to abnormal behavior may also be stored in the memory 111 for processing and outputting to the operator 190 of the control system 100. Furthermore, the monitoring system 130, the historical data 108, the predictive model 112, the controller 110, and the operator 190 may all be interconnected with each other via the communication network 116 such that each of these components may exchange necessary data with each other.

[0066] In an illustrative embodiment, as shown in FIG. 2, the monitoring system 130 is communicatively connected to the controller 110 and configured to monitor various parameters 104 of the electrolysis system 200. The monitoring system 130 communicates these parameters 104 to the controller 110 for further processing. Degradation of the electrolyzer cell stacks 204, 208 of the electrolysis 200 system may occur during typical usage of the electrolysis system 200. [0067] Excessive amounts of certain parameters 104, such as voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, fluid resistivity, and/or gas humidity, may lead to damage of the electrolyzer cell stacks 204, 208, thus reducing their lifespan. The controller 1 10 is configured to correlate at least one of the parameters 104 at one or several locations within the electrolysis system 200 to component performance, including cell stack 204, 208 performance. The continuous monitoring of the at least one parameter 104 is used to diagnose problems and predict performance and potential stack lifespan of the system 200.

[0068] In an exemplary embodiment, the electrolysis system 200 includes two electrolyzer cell stacks 204, 208 and a fluidic circuit 202 configured to circulate, inject, and purge fluid and other components to and from the electrolysis system 200. A person skilled in the art would understand that one or a variety of a number of components within the fluidic circuit 202, as well as more or less than two electrolyzer cell stacks 204, 208, may be utilized in the system 200. For example, the electrolysis system 200 may include one electrolyzer cell stack 204, and in other examples, the electrolysis system 200 may include three or more electrolyzer cell stacks.

[0069] Moreover, as described above, the electrolysis system 200 may be substantially similar to the electrolysis system 10. In particular, the components of the electrolysis system 200, in particular, for example, the electrolyzer cell stacks 204, 208, the connecting lines 206, 210, the oxygen and hydrogen separators 212, 216, the hydrogen drain tank 220, the oxygen drain tank 224, the various drains 221, 225, the various feeds 264, 268, the coolant input 227, and the polishing loop 236 and its associated components (the deionized water tank 240, the deionized water polishing pump 244, the water polishing heat exchanger 246, the deionized water resin tank 248, the deionized water pressure control valve 252, the recirculation fluidic connection 254, and the deionized water high pressure feed pumps 260), are all configured similarly to their corresponding components in the electrolysis system 10 described above.

[0070] As described above, the continual usage of the electrolysis system 200 may produce abnormal behaviors within components of the system 200, as well as reducing the time remaining on the lifespan of the components of the system 200, including the electrolyzer cell stacks 204, 208. In order to diagnose and predict the lifespan of the system components, the monitoring system 130 includes raw sensors, as well as soft sensors in some embodiments, to determine values of various operating parameters 104 present at various locations of the fluidic circuit 202. As will be described in greater detail below, the parameters 104 are fed to the controller 110 for further processing, diagnosis, and/or prediction of the lifespan of the system 200 components. The components of the system 200 that may be evaluated for abnormal behavior and lifespan may include any component of the system that is subject to wear over time, such as, but not limited to, pumps, heat exchangers, tanks, valves, and the cell stacks 204, 208.

[0071] The electrolysis system 200 includes at least one location 132 at which a raw sensor 133 is arranged that is configured to take a raw measurement of one or more of the parameters 104 at that location 132, as shown in FIG. 4. The system 200 further includes at least one second location 140 at which a first calculated measurement of the one or more parameters 104 is calculated at that location 140, as also shown in FIG. 4. The calculation of the first calculated measurement and other calculated measurements will be described in greater detail below.

[0072] In an illustrative embodiment, as shown in FIG. 4, the electrolysis system 200 includes four raw measurement locations 132, 134, 136, 138 each having at least one raw sensor 133, 135, 137, 139 to collect detected measurements associated therewith. An embodiment of the electrolysis system 200 further includes four soft sensor locations 140, 142, 144, 146 at which calculated measurements of one or more of the parameters 104 are determined. A person skilled in the art will understand that any number of required raw sensors 133, 135, 137, 139 and soft sensors 140, 142, 144, 146 may be utilized within the system 200 in order to accurately diagnose abnormal system 200 behavior and to predict the lifespan of the system 200 components.

[0073] Each sensor 133, 135, 137, 139 is configured to take a raw measurement of one or more of the parameters 104 at the respective location 132, 134, 136, 138 and feed the measurement to the controller 110. The controller 110 then stores the measurements in the memory 111 for later usage by the processor 112 for determination of the calculated measurements at the locations 140, 142, 144, 146. The controller 110 also aids with diagnosis of abnormal behaviors of system 200 components, as well as usage by the predictive model 120 for prediction of the lifespan of the system 200 components including the cell stacks 204, 208.

[0074] The locations 132, 134, 136, 138 at which the sensors 133, 135, 137, 139 are placed are areas within the fluidic circuit 202 that are minimally invasive. Additionally, the locations 132, 1 4, 136, 1 8 at which the sensors 133, 135, 137, 139 are placed are areas in which sensors may be unobtrusively arranged. Moreover, the sensors 133, 135, 137, 139 may be arranged in areas of the fluidic circuit 202 based on the desired parameter to be measured.

[0075] For example, in an illustrative embodiment, as shown in FIGS. 3-5, the parameter 104 to be measured is fluid conductivity of the water flowing through the fluidic circuit 202. As such, a first sensor 133 is arranged at a first location 132 directly at the output of the deionized water tank 240 between the tank 240 and the pump 244. A second sensor 135 is arranged at a second location 134 within the deionized water tank 240. A third sensor 137 is arranged at a third location 136 within the recirculation fluidic connection 254. A fourth sensor 139 is arranged at a fourth location 138 directly downstream of the deionized water high pressure feed pumps 260. Each of these locations 132, 134, 136, 138 have ample available physical space within the electrolysis system 200 for the placement of sensors.

[0076] Moreover, in order to accurately measure ion concentration of the water, each of the sensors 133, 135, 137, 139 is configured to measure the concentration of at least one of fluorine, platinum, iron, calcium, chromium, and/or nickel ions in the water. In other embodiments, the sensors may be placed in other locations or other components of the electrolysis system that are more conducive for measuring other parameters, such as temperature, pressure, flow, humidity, voltage, and current. In at least some embodiments, at least one sensor at one location is located downstream of the cell stacks 204, 208 in the fluidic circuit.

[0077] Unlike the raw sensors 133, 135, 137, 139, in some embodiments, the system 200 further includes soft sensors for calculated measurements at locations where placement of physical sensors is difficult or not possible. These calculated measurements may be used in conjunction with the raw measurements in order to increase the accuracy of the determination of abnormal behavior and the predicted lifespan of the system components 200 and the stacks 204, 208. In an illustrative embodiment, the controller 110 is configured to calculate calculated measurements at first, second, third, and fourth locations 140, 142, 144, 146, as shown in FIG. 4. [0078] The first location 140 may be located directly downstream of the deionized water heat exchanger 272. The second location 142 may be located directly upstream of the water returns to the cell stacks 204, 208 along a recirculation line 276 that is output from the deionized water heat exchanger 272. The third location 144 may be located directly upstream of the fluid output from the cell stacks 204, 208 enters the oxygen separator 212. The fourth location 146 may be located within the hydrogen drain tank 220.

[0079] In other embodiments, the location of the calculations may be in other locations of the system 200 that are more conducive for measuring other parameters. The parameters 104 may be temperature, pressure, flow, humidity, voltage, and current. In at least some embodiments, the location of at least one soft sensor 140, 142, 144, 146 is located downstream of the raw sensor 133, 135, 137, 139 located downstream of the cell stacks 204, 208 of the fluidic circuit 202.

[0080] In some embodiments, the soft sensing by the soft sensors is part of a pre-processing step of the controller 110 that is carried out before the comparison and diagnosis of abnormalities described herein. This pre-processing may further include filtering the raw and calculated data, validating and checking the raw and calculated data, creation of an exponentially weighted moving average (“EWMA”) plot/chart of the data, and storage of the data.

[0081] In an illustrative embodiment, the controller 110 is configured to calculate values of the one or more parameters 104 at these locations 140, 142, 144, 146. The calculated values or measurements of the parameters 104 are predicted values of these parameters 104 at those locations. The calculations may be executed by the processor 112 of the controller 110 and are based on input data received and stored within the memory 111, as shown in FIG. 2. In some embodiments, the input data may include the raw measurements received from the raw sensors of the system 200, such as the sensors 133, 135, 137, 139 described above. The input data may also include historical data 108, as also shown in FIG. 2. The processor 112 utilizes known models, known algorithms, and known operating conditions of the fluidic circuit 202 and the system 200 at these various locations in order to determine the calculated measurements at these locations.

[0082] For example, in embodiments that are measuring water conductivity, the controller 110 may utilize a mass-balance model to calculate the calculated measurements of water conductivity at the various locations 140, 142, 144, 146 described above. In embodiments that are measuring pressure and/or fluid flows, the controller 110 may utilize known thermodynamic and hydraulic models to calculate the calculated measurements of pressure and flow at the locations. In embodiments that are measuring temperature, the controller 110 may utilize known thermodynamic models as well as heat and mass-balance models to calculate the calculated measurements of temperature at the locations. In embodiments that are measuring humidity, the controller 110 may utilize known heat and mass-balance models to calculate the calculated measurements of humidity at the locations. A person skilled in the art will understand that some of these models and calculations may utilize the raw measurements obtained by the sensors, while others may only require historical or known data for these calculations. [0083] After these calculations are made by the controller 110, the controller 110 may first determine whether any of the system 200 components, including the cell stacks 204, 208 or any other component of the system 200 described above or known in the art, are operating within nominal bounds. In particular, the controller 110 may first compare the raw measurements taken by the sensors 1 3, 135, 137, 139 and compare these values to nominal measurements stored in the memory 111 of the controller 110. These measurements may include a single raw value or may include a measured rates of change (or rate of “recovery”) of a particular operating parameter. The controller 110 may then, in response to a particular raw measurement or rate of change being different than a nominal value or rate of change by a predetermined allowable limit, diagnose that this difference is indicative of an abnormal behavior of at least one component of the system 200.

[0084] In response to determining that the at least one component is behaving abnormally, the controller 110 then outputs a message to the operator 190 of the system 100, 200, and in some embodiments, may also output suggestions to the operator 190 for how to remedy the abnormal behavior and extend the lifespan of the at least one component. In some embodiments, if the operator 190 increases from 20% production to 100% production, several variables will change during this transient state until it reaches a new steady state. Monitoring the first raw measurements, in particular the rates of change, enables the operator 190 to act preemptively before the operating parameter reaches a dangerous value. In some embodiments, the system 100 may be further configured to utilize a control module or human-machine interface to communicate from the controller 110 to the operator 190.

[0085] For example, if it is determined that a water conductivity level is higher than a predetermined allowable limit of conductivity level, the controller 110 can be configured to reduce the operating temperature of the cell stack to reduce the rate of wear at the tradeoff of lower operating efficiency. This is an example of where the “correct” answer is based on the weighting of multiple factors (i.e. if a customer is most concerned with efficient production, they may opt to replace the stack). If a customer is most concerned with near-term availability, they may opt for the lower efficiency option. In some embodiments, if the system components begin operating abnormally, the controller 110 may include these conditions in the output message to alert the operator 190, for example, of associated lifespan loss due to this abnormal behaviour. [0086] Moreover, the system 100 may include suggestions by the manufacturer of the cell stacks 204, 208 or the other components of the system 200, or at least provide operators 190 with the information to make well-informed risk assessments for the system 200. In some embodiments, the controller 110 also takes the calculated measurements into account when diagnosing abnormal behavior, in particular by utilizing the calculated measurements along with the raw measurements to determine whether the calculated measurements deviate from the nominal values by a predetermined allowable limit.

[0087] In some embodiments, the controller 110 is further configured to diagnose the abnormality based on a certain amount of the time that the system 200 has been operating. For example, the diagnosis is based on a total time that the system 200 has been operational since its first usage. In some embodiments, the diagnosis is based on a total amount of hydrogen produced by the system 200. Moreover, in some embodiments, the diagnosis is based on a present operating condition of the system 200 or of specific components of the system 200. In some embodiments, the controller 110 is further configured to utilize operator requirements and compare nominal values of these requirements to measured (raw or calculated) values in order to make the diagnosis.

[0088] In some embodiments, the controller 110 is further configured to determine a predicted lifespan of the system 200 components including the electrolyzer cell stacks 204, 208. The controller 110 may input the raw measurements and calculated measurements into the predictive model 120, which may be stored and executed within the processor 112 of the controller 110, as shown in FIG. 2. Based on the raw and calculated measurements, the predictive model 120 then determines a predicted lifespan of the cell stacks 204, 208. The predictive model 120 may include many variables to determine particular predicted lifespan information for a variety of operator 190 specifications. For example, the predictive model 120 may simply perform an actual lifespan calculation of the system 200, in which the predicted lifespan of the system 200 component or components is determined based on the raw measurements, based on the calculated measurements, or based on the raw measurements and the calculated measurements. The deviation of the raw and calculated measurements from the nominal values may be variables indicative of the probable lifespan of the system 200 component or components. [0089] In some embodiments, the predictive model 120 further takes into consideration economic considerations of the operator 190 in the determination of the predicted lifespan. For example, in some scenarios, it is not always most economic to operate in a way that maximizes the lifespan of the system 200 component or components. Such scenarios may include the need to recover capital costs on equipment purchased by producing an optimal amount of hydrogen despite shortening life. This holistic approach allows operators 190 to define their performance metrics and targets and operate towards them, and thus the predictive model 120 can utilize such predetermined factors in the lifespan prediction and the controller 110 output to the operator 190. [0090] The ability to work together with an operator 190 to define what this holistic life requirement is, including production factors, actual equipment life, capital cost recovery, could also be taken into consideration by the predictive model 120. In some embodiments, the predictive model 120 may take into account a business model of the operator 190. For example, if the operator 190 is utilizing the electrolysis system 200 for grid load leveling (i.e. turning excess energy into hydrogen), the operator 190 may prioritize grid stability over electrolyzer life. This could be considered by the predictive model 120 for predicting lifespan, as well as considered by the controller 1 10 for recommending actions based on the diagnoses described above.

[0091] In an illustrative embodiment, the controller 110 is configured to utilize the raw measurements of ion concentration of the water at the locations 132, 134, 136, 138, as well as the calculated measurements of the ion concentration of the water at locations 140, 142, 144, 146, in order to determine how conductive or resistive the water is at a certain time. The controller 110 can be configured to then compare the raw and/or calculated measurements with at least one nominal value or rate of change in order to determine whether a system 200 component, such as a cell stack 204, 208, is operating abnormally, and then alert the operator 190 of the abnormality via an output message. In some embodiments, the system 100 may determine to shut down the electrolysis system 200 or lower the operating temperature of the system 200 if the deviation from the nominal value is too high. In some embodiments, the predetermined nominal values of the system 200 components and/or the stacks 204, 208 may be an industry standard, and/or may be selectively determined by a manufacturer of the system 200 and/or cell stacks 204, 208, and/or may be a standard length of lifespan based on the type, size, and specification of the system 200 components and/or cell stacks 204, 208.

[0092] Similarly, the predictive model 120 may utilize the raw measurements of ion concentration of the water at the locations 132, 134, 136, 138, as well as the calculated measurements of the ion concentration of the water at locations 140, 142, 144, 146, in order to determine how conductive or resistive the water is at a certain time. The amount of conductivity of the water is inversely proportional to the predicted lifespan of the electrolyzer cell stack, so the prediction model will determine that the lifespan of the system 200 components and/or stacks 204, 208 has decreased based on the amount of ion concentration in the water.

[0093] The controller 110 is configured to then, in response to a predetermined desired length of lifespan of the system 200 components and/or cell stacks 204, 208 being greater than the predicted lifespan of the system 200 components and/or stacks 204, 208 as determined by the controller 110 by a first amount of time, output a message to an operator 190 of the electrolysis system 200. In some embodiments, the predetermined desired length of lifespan of the system 200 components and/or stacks 204, 208 may be an industry standard, and/or may be selectively determined by a manufacturer of the system 200 components and/or cell stacks 204, 208, and/or may be a standard length of lifespan based on the type, size, and specification of the system 200 components and/or cell stacks 204, 208. [0094] In some embodiments, in response to the predetermined desired length of lifespan being greater than the predicted lifespan by a second amount of time that is greater than the first amount of time described above, the controller 110 is configured to shut down the electrolysis system 200 in addition to or as an alternative to sending a message to the operator 190. In some embodiments, in response to the predetermined desired length of lifespan being greater than the predicted lifespan by a second amount of time that is greater than the first amount of time described above, the controller 110 is configured to lower an overall operating temperature of the system 200 components and/or cell stacks 204, 208 in addition to or as an alternative to shutting down the electrolysis system 200 and sending a message to the operator 190.

[0095] In some embodiments, if the system 200 components and/or cell stacks 204, 208 begin operating in non-optimal conditions, the controller 110 may include these conditions in the prediction of the lifespan so as to alert the operator 190, for example, of associated lifespan loss due to this operating behaviour. Moreover, the system 100 may include suggestions by the manufacturer of the system 200 components and/or cell stacks 204, 208, or at least provide operators 190 with the information to make well-informed risk assessments for the system 200. The information sent to the operators 190 may also be utilized for scheduling preventative maintenance of the system 200 components.

[0096] In operation, the process of taking various raw measurements at differing locations in the system 200 and calculating calculated measurements at additional locations is continuously carried out. As the process is continuously carried out, previously determined raw and calculated measurements may be utilized as historical data by future calculations of calculated measurements in order to improve the accuracy of the future calculations. In some embodiments, the controller 110 may utilize machine learning and/or neural networks to continuously train itself to more accurately calculate the calculated measurements and determine potential abnormalities and the predicted lifespan of the system 200 components and/or stacks 204, 208. Moreover, the operator 190 may be continuously updated with repeated messages as the process is continuously repeated, and similarly, the system 200 may be repeatedly shut down or the temperature thereof lowered as needed.

[0097] Moreover, in some scenarios, it may be beneficial to the operator 190 that the predicted lifespan being less than a predetermined time of life value, as opposed to other embodiments in which the predicted lifespan is desired to be greater than the predetermined time of life value. The best efficiency point of a system when measured on the basis of “cost to produce hydrogen” does not always align with the best efficiency point of a system measured by lifespan or production efficiency. If an operator 190 desires to run a system in the most economical way possible, it may not always result in the longest life. This is a tradeoff the operator 190 (or owner(s) of the system) will need to decide on and may result in shorter life, but may result in a lower cost scenario.

[0098] In general, operators 190 are provided with the ability to define what the targets are, and based on the unique set of requirements, set criteria to meet that, set up advisements if they stray away from this, and later provide indication of the life of the system if they continue on said path. For example, running the system 200 colder, or lowering the operating temperature of the system, results in longer life, but less efficient performance (e.g. more costly and therefore generally not preferred). Considering all this information holistically would allow the operator 190 to determine what the best targets are for their purposes.

[0099] The continuous monitoring of the parameters 104 can be used as predictors and monitors of system performance, allowing operators 190 to closely monitor the life of the system 200 components and/or cell stacks 204, 208. Accurate monitoring can allow operators 190 to project the end of life of the cell stack 204, 208 and have better resolution on these dates, to extend the life of expensive cell stack assemblies. This extension of operating life translates to significant savings by the operating team and enable improved risk monitoring plant-wide. Additionally, the soft sensors may advantageously be sold to existing customers without needing to make modification to existing cell stacks, and also would not be limited to new equipment only.

[0100] The disclosed embodiments would be scalable to all sizes of electrolysis facilities, and could potentially provide even more value for facilities operating cell stacks of ten or more stacks. Moreover, because the disclosed systems and methodologies can be adapted to existing installations as a software upgrade, no invasive modifications of existing systems would be required (e.g. as in advanced internal sensors). The disclosed systems and methods can leverage existing reliable sensing technologies in obtaining empirical data for the analysis described herein. The disclosed systems and methods can reduce customer operating expenses and improve the ability to coordinate or stagger cell stack replacements.

[0101] As shown in FIG. 6, a method 300 of monitoring at least one operating parameter in an electrolysis system for forecasting lifespan of an electrolyzer cell stack of the electrolysis system includes a first operation 302 of measuring the at least one operating parameter using at least one sensor arranged in at least one location, and in particular, at a first location on a fluidic circuit of the electrolysis system with a first sensor to obtain a first raw measurement of the at least one operating parameter.

[0102] The method 300 further includes a second operation 304 of pre-processing the measurements obtained from operation 302, which may include filtering raw data, utilizing soft sensors, validating/checking data, creating an exponentially weighted moving average plot/chart of the data, and storing the data. The second operation 304 may include receiving, at a controller, the first raw measurement, the controller including at least one computer-readable storage medium. The second operation 304 may further include calculating, via the controller, a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different than the first location.

[0103] The method 300 further includes a third operation 306 of interpreting, or comparing, via the controller, at least one of (i) the first value of the first raw measurement to a predetermined nominal measurement or (ii) the first rate of change of the first raw measurement to a predetermined nominal rate of change. The comparison, or interpretation, may take into account a present operating condition 307 of the system, the age of the system determined via an age counter 308, a certain criteria 309 of the system including expected values and levels, and owner/operator requirements. The third operation 306 may further include diagnosing, via the controller, at least one abnormality of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differing from the predetermined nominal measurement by a first amount or (ii) the first rate of change of the first raw measurement differing from the predetermined nominal rate of change by a first rate amount.

[0104] The method 300 may further include a fourth operation 310 of communicating the interpretation and diagnosis of an abnormality to a control module or human-machine interface. The method 300 further includes a fifth operation 312, in response to the diagnosis of the at least one abnormality, outputting a first message, via the controller, to an operator of the electrolysis system indicative of the at least one abnormality. The message may define specific actions for the operator to take to correct the abnormality.

[0105] The following described aspects of the present disclosure are contemplated and nonlimiting:

[0106] A first aspect of the present disclosure relates to a method of monitoring at least one operating parameter in an electrolysis system for optimizing the operating lifespan of at least one component of the electrolysis system. The method includes measuring the at least one operating parameter at a first location of the electrolysis system with a first sensor to obtain a first raw measurement of the at least one operating parameter, the first raw measurement including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter; receiving, at a controller, the first raw measurement, the controller including at least one computer-readable storage medium; comparing, via the controller, at least one of (i) the first value of the first raw measurement to a predetermined nominal measurement or (ii) the first rate of change of the first raw measurement to a predetermined nominal rate of change; diagnosing, via the controller, at least one abnormality of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differing from the predetermined nominal measurement by a first amount or (ii) the first rate of change of the first raw measurement differing from the predetermined nominal rate of change by a first rate amount; and in response to the diagnosis of the at least one abnormality, outputting a first message, via the controller, to an operator of the electrolysis system indicative of the at least one abnormality.

[0107] A second aspect of the present disclosure relates to an electrolysis system. The electrolysis system includes at least one component including at least one of a pump, a heat exchanger, a tank, or a valve; an electrolyzer cell stack configured to separate input water into hydrogen and oxygen; a controller including at least one computer-readable storage medium; and a first sensor operably connected to the controller and configured to measure at least one operating parameter at a first location of the electrolysis system to obtain a first raw measurement of the at least one operating parameter. The first raw measurement includes at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter. The controller is configured to compare at least one of (i) the first value of the first raw measurement to a predetermined nominal measurement or (ii) the first rate of change of the first raw measurement to a predetermined nominal rate of change; diagnose at least one abnormality of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differing from the predetermined nominal measurement by a first amount or (ii) the first rate of change of the first raw measurement differing from the predetermined nominal rate of change by a first rate amount; and in response to the diagnosis of the at least one abnormality, output a first message, via the controller, to an operator of the electrolysis system indicative of the at least one abnormality.

[0108] In the first aspect of the present disclosure, the method may further include determining, via the controller, a predicted lifespan of the at least one component including a predicted length of lifespan based on the first raw measurement; comparing, via the controller, the predicted length of lifespan with a predetermined length of lifespan of the at least one component; and in response to the predetermined length of lifespan being different than the predicted length of lifespan by a first amount of time, outputting a second message, via the controller, to the operator of the electrolysis system indicative of the predicted lifespan. In the first aspect of the present disclosure, the method may further include calculating, via the controller, a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different than the first location, the first calculated measurement including at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of the at least one abnormality may be further based on at least one of (i) the first calculated value of the first calculated measurement differing from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differing by a first calculated rate amount. The determining, via the controller, of the predicted lifespan of the at least one component including the predicted length of lifespan may be based on at least one of the first raw measurement and the first calculated measurement.

[0109] In the first aspect of the present disclosure, the method may further include, in response to the predetermined length of time differing from the predicted length of lifespan by a second amount of time that is greater than the first amount of time, shutting down the electrolysis system. In the first aspect of the present disclosure, the diagnosis of the at least one abnormality may be further based on the at least one of a total age of the electrolysis system, a total amount of hydrogen already produced by the electrolysis system, or a present operating condition of the electrolysis system. In the first aspect of the present disclosure, the at least one operating parameter may include at least one of voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, or gas humidity. The at least one component may include at least one of an electrolyzer cell stack, a pump, a heat exchanger, a tank, or a valve of the electrolysis system.

[01 10] In the first aspect of the present disclosure, the method may further include receiving, at the controller, at least one historical measurement of the at least one operating parameter at the first location of the electrolysis system that was measured by the first sensor prior to the first raw measurement; and calculating, via the controller, a second calculated measurement of the at least one operating parameter at the second location based at least in part on the first raw measurement and the at least one historical measurement. In the first aspect of the present disclosure, the diagnosis of the at least one abnormality may be further based on the at least one historical measurement differing from the predetermined nominal measurement by a third amount. The determining of the predicted lifespan may be further based on the first raw measurement, the first calculated measurement, the at least one historical measurement, and the second calculated measurement. In the first aspect of the present disclosure, the method may further include measuring the at least one operating parameter at a plurality of additional first locations of the electrolysis system different than the first location with a plurality of additional sensors to obtain an additional raw measurement of the at least one operating parameter at each additional location of the plurality of additional locations to establish a plurality of additional raw measurements; receiving, at the controller, the plurality of additional raw measurements; calculating, via the controller, a plurality of additional calculated measurements of the at least one operating parameter at respective additional second locations of the electrolysis system different than the first location, the plurality of additional first locations, and the additional second locations based at least in part on the plurality of additional raw measurements; and determining, via the controller, the predicted lifespan of the electrolyzer cell stack based on the first raw measurement, the first calculated measurement, the at least one historical measurement, the second calculated measurement, the plurality of additional raw measurements, and the plurality of additional calculated measurements.

[0111] In the second aspect of the present disclosure, the controller may be further configured to determine a predicted lifespan of the at least one component including a predicted length of lifespan based on the first raw measurement, compare, the predicted length of lifespan with a predetermined length of lifespan of the at least one component, and, in response to the predetermined length of lifespan being different than the predicted length of lifespan by a first amount of time, output a second message to the operator of the electrolysis system indicative of the predicted lifespan. In the second aspect of the present disclosure, the electrolysis system may further include a first soft sensor configured to calculate a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different than the first location. The first calculated measurement may include at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter. The diagnosis of the at least one abnormality via the controller may be further based on at least one of (i) the first calculated value of the first calculated measurement differing from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differing by a first calculated rate amount. The determining of the predicted lifespan of the at least one component via the controller may include the predicted length of lifespan is based on at least one of the first raw measurement and the first calculated measurement. In the second aspect of the present disclosure, the at least one operating parameter may include an amount of conductivity of water flowing through the electrolysis system. The amount of conductivity of the water may be inversely proportional to the predicted lifespan of the electrolyzer cell stack. In the second aspect of the present disclosure, the amount of conductivity of the water may be determined based on an ion concentration of the water. In the second aspect of the present disclosure, the ion concentration of the water may include measurements of a concentration of at least one of fluorine, platinum, iron, calcium, chromium, and nickel.

[0112] In the second aspect of the present disclosure, the first location of the electrolysis system may be located downstream of the electrolyzer stack and the second location of the electrolysis system may be located downstream of the first location in the electrolyzer system. In the second aspect of the present disclosure, the electrolysis system may further include a hydrogen separator located downstream of and fluidically connected to the electrolyzer stack of the electrolysis system; a polishing loop fluidically connected to the hydrogen separator and configured to treat drain flow from the hydrogen separator for recirculation into an oxygen separator, the oxygen separator located downstream of and fluidically connected to the electrolyzer stack and downstream of and fluidically connected to the polishing loop; and a water circulation pump located downstream of and fluidically connected to the oxygen separator and configured to direct water from the oxygen separator to an input of the electrolyzer stack. In the second aspect of the present disclosure, the first location of the electrolysis system may be located along a first fluidic line that extends between and interconnects the polishing loop and the oxygen separator. The second location of the electrolysis system may be located along a second fluidic line that extends between and interconnects the water circulation pump and the input of the electrolyzer. In the second aspect of the present disclosure, the electrolysis system may further include a second, third, and fourth sensor arranged within the polishing loop and each operably connected to the controller. Each of the second, third, and fourth sensors may be configured to measure the water conductivity at a third, fourth, and fifth location within the polishing loop, respectively, and the second, third, and fourth sensors may be configured to obtain second, third, and fourth raw measurements of the water conductivity, respectively, and send the second, third, and fourth raw measurements to the controller. The electrolysis system may also further include a second soft sensor configured for calculations regarding a sixth location directly downstream of the hydrogen separator, a third soft sensor configured for calculations regarding a seventh location directly upstream of the oxygen separator, and a fourth soft sensor configured for calculations regarding an eighth location along a third fluidic line that extends from the water circulation pump to the polishing loop. Each of the second, third, and fourth soft sensors may be configured to calculate second, third, and fourth calculated measurements of the water conductivity at the sixth, seventh, and eighth locations, respectively, based at least in part on the first, second, third, and fourth raw measurements. The controller may be further configured to determine the predicted lifespan of the at least one component including the predicted length of lifespan based on the first, second, third, and fourth raw measurements and the first, second, third, and fourth calculated measurements.

[0113] In the second aspect of the present disclosure, the diagnosis of the at least one abnormality may be further based on the at least one of a total age of the electrolysis system, a total amount of hydrogen already produced by the electrolysis system, or a present operating condition of the electrolysis system.

[0114] While the disclosure has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.

[0115] There are a plurality of advantages of the present disclosure arising from the various features of the method, apparatus, and system described herein. It will be noted that alternative embodiments of the method, apparatus, and system of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the method, apparatus, and system that incorporate one or more of the features of the present invention and fall within the spirit and scope of the present disclosure as defined by the appended claims.

[0116] The features illustrated or described in connection with one exemplary embodiment may be combined with any other feature or element of any other embodiment described herein. Such modifications and variations are intended to be included within the scope of the present disclosure. Further, a person skilled in the art will recognize that terms commonly known to those skilled in the art may be used interchangeably herein.

[0117] As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the presently described subject matter are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Specified numerical ranges of units, measurements, and/or values comprise, consist essentially or, or consist of all the numerical values, units, measurements, and/or ranges including or within those ranges and/or endpoints, whether those numerical values, units, measurements, and/or ranges are explicitly specified in the present disclosure or not.

[0118] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terms “first”, “second”, “third” and the like, as used herein do not denote any order or importance, but rather are used to distinguish one element from another. The term “or” is meant to be inclusive and mean either or all of the listed items. In addition, the terms “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect.

[0119] Moreover, unless explicitly stated to the contrary, embodiments “comprising”, “including,” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property. The term “comprising” or “comprises” refers to a composition, compound, formulation, or method that is inclusive and does not exclude additional elements, components, and/or method steps. The term “comprising” also refers to a composition, compound, formulation, or method embodiment of the present disclosure that is inclusive and does not exclude additional elements, components, or method steps.

[0120] The phrase “consisting of’ or “consists of’ refers to a compound, composition, formulation, or method that excludes the presence of any additional elements, components, or method steps. The term “consisting of’ also refers to a compound, composition, formulation, or method of the present disclosure that excludes the presence of any additional elements, components, or method steps.

[0121] The phrase “consisting essentially of’ or “consists essentially of’ refers to a composition, compound, formulation, or method that is inclusive of additional elements, components, or method steps that do not materially affect the characteristic (s) of the composition, compound, formulation, or method. The phrase “consisting essentially of’ also refers to a composition, compound, formulation, or method of the present disclosure that is inclusive of additional elements, components, or method steps that do not materially affect the characteristic(s) of the composition, compound, formulation, or method steps.

[0122] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, and “substantially” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0123] As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances, the modified term may sometimes not be appropriate, capable, or suitable.

[0124] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used individually, together, or in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the subject matter set forth herein without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the disclosed subject matter, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter described herein should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0125] This written description uses examples to disclose several embodiments of the subject matter set forth herein, including the best mode, and also to enable a person of ordinary skill in the art to practice the embodiments of disclosed subject matter, including making and using the devices or systems and performing the methods. The patentable scope of the subject matter described herein is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

WHAT IS CLAIMED IS:

1. A method of monitoring at least one operating parameter in an electrolysis system for optimizing the operating lifespan of at least one component of the electrolysis system, the method comprising: measuring the at least one operating parameter at a first location of the electrolysis system with a first sensor to obtain a first raw measurement of the at least one operating parameter, the first raw measurement including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter; receiving, at a controller, the first raw measurement, the controller including at least one computer-readable storage medium; comparing, via the controller, at least one of (i) the first value of the first raw measurement to a predetermined nominal measurement or (ii) the first rate of change of the first raw measurement to a predetermined nominal rate of change; diagnosing, via the controller, at least one abnormality of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differing from the predetermined nominal measurement by a first amount or (ii) the first rate of change of the first raw measurement differing from the predetermined nominal rate of change by a first rate amount; and in response to the diagnosis of the at least one abnormality, outputting a first message, via the controller, to an operator of the electrolysis system indicative of the at least one abnormality.

2. The method of claim 1 further comprising: determining, via the controller, a predicted lifespan of the at least one component including a predicted length of lifespan based on the first raw measurement; comparing, via the controller, the predicted length of lifespan with a predetermined length of lifespan of the at least one component; and in response to the predetermined length of lifespan being different than the predicted length of lifespan by a first amount of time, outputting a second message, via the controller, to the operator of the electrolysis system indicative of the predicted lifespan.

3. The method of claim 2, further comprising: calculating, via the controller, a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different than the first location, the first calculated measurement including at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter, wherein the diagnosis of the at least one abnormality is further based on at least one of (i) the first calculated value of the first calculated measurement differing from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differing by a first calculated rate amount, and wherein the determining, via the controller, of the predicted lifespan of the at least one component including the predicted length of lifespan is based on at least one of the first raw measurement and the first calculated measurement.

4. The method of claim 3, further comprising: shutting down the electrolysis system in response to the predetermined length of time differing from the predicted length of lifespan by a second amount of time that is greater than the first amount of time.

5. The method of claim 3, wherein the diagnosis of the at least one abnormality is further based on the at least one of a total age of the electrolysis system, a total amount of hydrogen already produced by the electrolysis system, or a present operating condition of the electrolysis system.

6. The method of claim 3, wherein the at least one operating parameter includes at least one of voltage, current, temperature, pressure, fluid flow rate, fluid conductivity, or gas humidity, and wherein the at least one component includes at least one of an electrolyzer cell stack, a pump, a heat exchanger, a tank, or a valve of the electrolysis system.

7. The method of claim 3, further comprising: receiving, at the controller, at least one historical measurement of the at least one operating parameter at the first location of the electrolysis system that was measured by the first sensor prior to the first raw measurement; and calculating, via the controller, a second calculated measurement of the at least one operating parameter at the second location based at least in part on the first raw measurement and the at least one historical measurement.

8. The method of claim 7, wherein the diagnosis of the at least one abnormality is further based on the at least one historical measurement differing from the predetermined nominal measurement by a third amount, and wherein the determining of the predicted lifespan is further based on the first raw measurement, the first calculated measurement, the at least one historical measurement, and the second calculated measurement.

9. The method of claim 8, further comprising: measuring the at least one operating parameter at a plurality of additional first locations of the electrolysis system different than the first location with a plurality of additional sensors to obtain an additional raw measurement of the at least one operating parameter at each additional location of the plurality of additional locations to establish a plurality of additional raw measurements; receiving, at the controller, the plurality of additional raw measurements; calculating, via the controller, a plurality of additional calculated measurements of the at least one operating parameter at respective additional second locations of the electrolysis system different than the first location, the plurality of additional first locations, and the additional second locations based at least in part on the plurality of additional raw measurements; and determining, via the controller, the predicted lifespan of the electrolyzer cell stack based on the first raw measurement, the first calculated measurement, the at least one historical measurement, the second calculated measurement, the plurality of additional raw measurements, and the plurality of additional calculated measurements.

10. An electrolysis system, comprising: at least one component including at least one of a pump, a heat exchanger, a tank, or a valve; an electrolyzer cell stack configured to separate input water into hydrogen and oxygen; a controller including at least one computer-readable storage medium; a first sensor operably connected to the controller and configured to measure at least one operating parameter at a first location of the electrolysis system to obtain a first raw measurement of the at least one operating parameter, the first raw measurement including at least one of a first value of the at least one operating parameter or a first rate of change of the at least one operating parameter, wherein the controller is configured to: compare at least one of (i) the first value of the first raw measurement to a predetermined nominal measurement or (ii) the first rate of change of the first raw measurement to a predetermined nominal rate of change; diagnose at least one abnormality of the at least one component of the system based on at least one of (i) the first value of the first raw measurement differing from the predetermined nominal measurement by a first amount or (ii) the first rate of change of the first raw measurement differing from the predetermined nominal rate of change by a first rate amount; and in response to the diagnosis of the at least one abnormality, output a first message indicative of the at least one abnormality via the controller to an operator of the electrolysis system .

11. The electrolysis system of claim 10, wherein the controller is further configured to determine a predicted lifespan of the at least one component including a predicted length of lifespan based on the first raw measurement, compare, the predicted length of lifespan with a predetermined length of lifespan of the at least one component, and, in response to the predetermined length of lifespan being different than the predicted length of lifespan by a first amount of time, output a second message to the operator of the electrolysis system indicative of the predicted lifespan.

12. The electrolysis system of claim 11 , further comprising: a first soft sensor configured to calculate a first calculated measurement of the at least one operating parameter at a second location of the electrolysis system different than the first location, the first calculated measurement including at least one of a first calculated value of the at least one operating parameter or a first calculated rate of change of the at least one operating parameter, wherein the diagnosis of the at least one abnormality via the controller is further based on at least one of (i) the first calculated value of the first calculated measurement differing from a predetermined nominal calculated measurement by a first calculated amount or (ii) the first calculated rate of change of the first calculated measurement differing by a first calculated rate amount, and wherein the determining of the predicted lifespan of the at least one component via the controller including the predicted length of lifespan is based on at least one of the first raw measurement and the first calculated measurement.

13. The electrolysis system of claim 12, wherein the at least one operating parameter includes an amount of conductivity of water flowing through the electrolysis system, and wherein the amount of conductivity of the water is inversely proportional to the predicted lifespan of the electrolyzer cell stack.

14. The electrolysis system of claim 13, wherein the amount of conductivity of the water is determined based on an ion concentration of the water.

15. The electrolysis system of claim 14, wherein the ion concentration of the water includes measurements of a concentration of at least one of fluorine, platinum, iron, calcium, chromium, and nickel.

16. The electrolysis system of claim 12, wherein the first location of the electrolysis system is located downstream of the electrolyzer stack and the second location of the electrolysis system is located downstream of the first location in the electrolyzer system.

17. The electrolysis system of claim 16, further comprising: a hydrogen separator located downstream of and fluidically connected to the electrolyzer stack of the electrolysis system; a polishing loop fluidically connected to the hydrogen separator and configured to treat drain flow from the hydrogen separator for recirculation into an oxygen separator, the oxygen separator located downstream of and fluidically connected to the electrolyzer stack and downstream of and fluidically connected to the polishing loop; and a water circulation pump located downstream of and fluidically connected to the oxygen separator and configured to direct water from the oxygen separator to an input of the electrolyzer stack.

18. The electrolysis system of claim 17, wherein the first location of the electrolysis system is located along a first fluidic line that extends between and interconnects the polishing loop and the oxygen separator, and wherein the second location of the electrolysis system is located along a second fluidic line that extends between and interconnects the water circulation pump and the input of the electrolyzer.

19. The electrolysis system of claim 18, further comprising: a second, third, and fourth sensor arranged within the polishing loop and each operably connected to the controller, each of the second, third, and fourth sensors being configured to measure the water conductivity at a third, fourth, and fifth location within the polishing loop, respectively, the second, third, and fourth sensors being configured to obtain second, third, and fourth raw measurements of the water conductivity, respectively, and send the second, third, and fourth raw measurements to the controller; and a second soft sensor configured for calculations regarding a sixth location directly downstream of the hydrogen separator, a third soft sensor configured for calculations regarding a seventh location directly upstream of the oxygen separator, and a fourth soft sensor configured for calculations regarding an eighth location along a third fluidic line that extends from the water circulation pump to the polishing loop, each of the second, third, and fourth soft sensors being configured to calculate second, third, and fourth calculated measurements of the water conductivity at the sixth, seventh, and eighth locations, respectively, based at least in part on the first, second, third, and fourth raw measurements, wherein the controller is further configured to determine the predicted lifespan of the at least one component including the predicted length of lifespan based on the first, second, third, and fourth raw measurements and the first, second, third, and fourth calculated measurements.

20. The electrolysis system of claim 12, wherein the diagnosis of the at least one abnormality is further based on the at least one of a total age of the electrolysis system, a total amount of hydrogen already produced by the electrolysis system, or a present operating condition of the electrolysis system.