Digital twin model development and validation for megawatt-scale alkaline water electrolysis.

This article focuses on the development and validation of a digital twin model for a megawatt-scale alkaline water electrolysis hydrogen production system. The model integrates multivariable empirical equations for key parameters including cell voltage, Faraday efficiency, hydrogen concentration in oxygen, and system pressure, explicitly incorporating the effects of temperature, pressure, and alkaline solution (lye) flow rate. Using operational data from a 1 MW electrolyzer, the study employs Matlab for nonlinear fitting and implements real-time control via a programmable logic controller (PLC), enabling simulation of wide power fluctuations and safety boundary analysis. The digital twin framework provides a virtual experimental platform to optimize system performance and safety, particularly under variable renewable energy inputs, while highlighting the need for further refinement in dynamic modeling and multi-variable control strategies.