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Optimal design of megawatt-scale proton exchange membrane water electrolysis module by hierarchical multi-scale modeling

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  • Fu, Kaihao
  • Li, Ping
  • Li, Xinyuan
  • Cao, Chenxi
  • He, Wangli
  • Du, Wenli
  • Qian, Feng

Abstract

Proton exchange membrane water electrolyzers (PEMWEs) play a crucial role in the long-term utilization of large-scale, intermittent renewable energy sources such as wind and solar power. This study addresses the critical, unresolved issue of optimizing megawatt-scale PEMWE cluster architectures by developing an equivalent transport resistance network model that incorporates the coupled multi-scale flow and electric fields. Within 5 % error and with full techno-economic metrics returned in minutes, a systematic comparison of hierarchical PEMWE layouts pinpoints the pivotal role of the bipolar plate-electrolysis cell configuration; an optimized 1 MW module with fewer stacks can deliver greater than 231 Nm3/h of hydrogen at a cost of less than 1.50 CNY/Nm3. Our approach establishes a theoretical foundation and provides practical design insights for implementation of advanced commercial-scale water electrolysis technologies towards net-zero energy and chemicals production.

Suggested Citation

  • Fu, Kaihao & Li, Ping & Li, Xinyuan & Cao, Chenxi & He, Wangli & Du, Wenli & Qian, Feng, 2026. "Optimal design of megawatt-scale proton exchange membrane water electrolysis module by hierarchical multi-scale modeling," Applied Energy, Elsevier, vol. 408(C).
    • Handle: RePEc:eee:appene:v:408:y:2026:i:c:s0306261925020550
    DOI: 10.1016/j.apenergy.2025.127325
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