DC Electrical systems for Green Hydrogen production
Green hydrogen, produced through water electrolysis powered by renewable energy, is emerging as a critical solution for decarbonising heavy industry, transportation, and energy storage. G Corner has been at the forefront of this rapidly growing sector since 2015, bringing decades of high-current DC electrical expertise to the unique challenges of hydrogen electrolyser design and operation.
Enquire
Introduction
Green hydrogen production is scaling rapidly, and the electrical infrastructure that supports it must scale with equal precision and reliability.
At its core, green hydrogen is produced through electrolysis, a process that places significant demands on DC power distribution systems in terms of current levels, voltage management, and system efficiency. As electrolyser technology continues to evolve, the design of supporting DC electrical systems requires both deep engineering expertise and the flexibility to work alongside emerging technologies. G Corner brings both.
Drawing on decades of experience in chlorine electrolysis, a closely related industrial process, we have developed tailored busbar system solutions for both primary routes of green hydrogen production, supporting customers from prototype and pre-production stage through to full-scale plant delivery.
PEM (Proton Exchange Membrane) electrolysers
Alkaline water electrolysis (AWE)
Renewable energy projects
As green hydrogen installations grow in scale, the DC current loads placed on busbar systems increase significantly. AWE electrolysers in particular operate at much higher currents than PEM systems, creating complex engineering requirements around conductor sizing, current distribution, and thermal management. G Corner's engineering team has extensive experience designing busbar systems for very high-current DC applications across base metal refining and chlorine electrolysis. We apply that same rigour to hydrogen electrolyser projects, developing detailed electrical and thermal performance calculations to ensure systems are optimised for the specific current and voltage profile of each installation.
Uneven current distribution across electrolyser stacks reduces hydrogen output efficiency, accelerates electrode degradation, and increases the frequency of maintenance interventions. In an industry where levelised cost of hydrogen is a critical commercial metric, electrical system inefficiencies have a direct impact on project economics. G Corner designs busbar systems that maintain precise, uniform current distribution across all electrolyser cells, minimising resistance at every joint and connection point. Our in-house millivolt drop testing validates resistance levels before despatch, and commissioning verification on site confirms performance under operating conditions.
The green hydrogen industry is moving quickly from demonstration projects to commercial-scale plants. Many customers are scaling electrolyser capacity in phases, requiring DC electrical systems that can be designed for future expansion from the outset without disrupting operational units already in service. G Corner works with customers at the earliest stages of project development, including feasibility studies, R&D collaboration, and prototyping, to ensure that electrical systems are engineered with scalability built in. Our experience across multiple electrolyser generations and technology types means we understand how system requirements evolve as capacity grows.
Hydrogen production facilities carry inherent safety risks associated with the storage and handling of a highly flammable gas. Electrical system reliability is therefore not just a commercial concern but a safety imperative. Unplanned outages caused by electrical failures introduce risk as well as cost. G Corner engineers systems for minimal maintenance from the outset, using quality materials, controlled manufacturing, and rigorous pre-despatch testing to deliver installations that perform reliably from day one. We support this with comprehensive maintenance documentation, operator training, and periodic specialist site inspections.
What our customers say about us
"G Corner are a very professional and reliable supplier who have a demonstrated ability in handling design changes and additions yet still meeting project delivery requirements and I have no hesitation in recommending them to anyone for this type of work."
Contact our team
