A combined mechanical and fluid dynamic study of a medium power alkaline electrolyzer with prototype validation

Abstract This study presents the design, simulation, and experimental validation of a medium-power alkaline electrolyzer with a focus on structural, fluidics, and seal-ing performance. We evaluated the influence of electrode separator thickness on fluid dynamics and internal resistance, determining an optimal thickness of 3 mm. Mechanical simulations revealed that the structure remains intact under internal pressures of up to 15 bar, with acceptable stress distributions across all com- ponents. Fluidics tests demonstrated a uniform electrolyte distribution within the cells, ensuring optimal electrochemical performance. A two-cell stack was constructed as a prototype to validate sealing and flow behavior under realistic conditions. Hydraulic tests confirmed that the prototype maintained hermetic sealing at pressures up to 10 bar, with adjustments needed for 15 bar. Preliminary electrochemical testing using a KOH 30% wt. electrolyte confirmed stable oper- ation, although the cell voltage suggests that further optimization is required to reach high-performance benchmarks. Overall, the results highlight the robustness of the proposed design and its potential for future scale-up in green hydrogen production systems.