Modeling and optimal sizing of thyristor rectifiers for high-power hydrogen electrolyzers

Thyristor rectifiers are currently the most common solution for supplying high-power electrolyzers. These rectifiers typically include a dc inductance, which significantly increases system costs. However, this inductance can be avoided by relying solely on ac-side inductances, required for grid current harmonic filtering, although this approach introduces specific challenges. Traditional analytical models of thyristor rectifiers are unable to determine the electrolyzer operating point for a given firing angle and may lead to incorrect system sizing, ultimately preventing the converter from delivering nominal power. This limitation arises from the fact that existing models are formulated for inductive or constant-current loads, whereas electrolyzers exhibit electrical behavior closer to constant-voltage loads. In this paper, a novel analytical model of 6- and 12-pulse thyristor rectifiers with constant-voltage load is developed. The model enables the analysis and optimal sizing of thyristor rectifiers directly connected to electrolyzers without a dc-side inductance. Its accuracy has been validated through both simulations and experimentally using a laboratory-scale prototype. Furthermore, the model has been applied to optimally size a 12-pulse rectifier supplying a 5.5 MW electrolyzer, demonstrating its suitability for the design of thyristor rectifier systems in industrial-scale electrolysis applications and highlighting its advantages over traditional approaches.