Eliminating Liquid Carryover from Hydrogen Separators with MySep Studio
Kranji Solutions combined its separation expertise with MySep Studio software to diagnose and resolve liquid carryover issues in a hydrogen separator. Using detailed modelling and analysis, the team identified the causes of demi-water entrainment and evaluated separator performance under operating conditions. This enabled the development of an effective solution that eliminated carryover and improved the reliability of the PEM fuel cell system.
BUSINESS PROBLEM
A 500 kW PEM fuel cell power system was tested and commissioned. This system generates electricity by reacting hydrogen with oxygen in a fuel cell stack and requires a steady supply of pure hydrogen with controlled humidity. Any free water droplets entering the stack can disrupt membrane hydration, reduce efficiency, or even cause damage. During operation, the upstream demi-water/H₂ separator experienced liquid carryover, leading to operational issues.
INDEPENDENT MYSEP STUDIO ANALYSIS
Optimizing the separation of demi-water in the hydrogen separator was essential to achieve trouble-free fuel cell operation. At first glance, the H₂ separator featured a compact design with a non-ideal internal configuration. MySep Studio analysis revealed favorable inlet conditions, with relatively large demi-water droplets and low mist fractions. However, the existing internals made liquid re-entrainment and H₂ maldistribution unavoidable.
Using MySep Studio, an optimized retrofit design was developed, addressing these issues and ensuring improved separation performance and reliable operation.
SOLUTION
The retrofit design demonstrated excellent simulated performance. The H₂ separator’s overall separation efficiency is predicted to exceed 99.99%, capturing droplets in the 10–20 micron range depending on operating conditions. Kranji Solutions provided detailed process arrangement drawings, enabling the client to procure the required retrofit internals.
After implementing the retrofit, the client verified the H₂ separator’s performance in their laboratory, confirming that no liquid carryover occurred under both normal and peak operating conditions.
SUMMARY
This Kranji retrofit successfully eliminated liquid carryover, ensuring reliable and efficient H₂ supply to the PEM fuel cell system. This project demonstrates how Kranji Solutions’ expertise combined with MySep Studio simulation tools deliver practical, high-performance separation solutions.
