High Efficiency Large PEM Electrolyzers

Size: px

Start display at page:

Download "High Efficiency Large PEM Electrolyzers"

Lester Moore
6 years ago
Views:

1 High Efficiency Large PEM Electrolyzers Monjid Hamdan Director of Engineering Giner, Inc. 89 Rumford Ave, Newton, Ma

2 Outline Giner, Inc. Overview Advancements in Efficiency New Membranes Coming to Market Performance & Efficiency Lifetime Durability Cost Reduction Innovative Stack Designs High Pressure Electrolysis Performance & Validation Large Scale PEM Electrolyzer Wrap-Up 2

3 GINER, Inc. Giner, Inc. Founded in 1973 Specializing in research & development of PEM based electrochemical technology and systems Since 2005 Giner has accelerated growth Key driver has been the manufacturing of PEM electrolyzers to OEMs Global leader in Polymer Electrolyte Membrane (PEM)-based electrolyzers Highest efficiency technology for commercial applications Core Mission: Provide Innovative PEM Technologies with the Highest Efficiencies at the Lowest Costs to Developing Hydrogen Markets Staff: 65 people Synergy of Giner, Inc. Technologies 3

4 Giner Electrolyzers Electrolyzer Stacks Electrolyzer Systems Vehicle Applications Differential Pressure Balanced Pressure Anode Feed Cathode Feed Vapor Feed Static Feed Regenerative (Combined Fuel-Cell & Electrolyzer) Electrochemical H 2 -Compressors Oxygen Concentrators On-Site H 2 Generators Laboratory Hydrogen Life Support 4

5 Giner, Inc. Overview Advancements in Efficiency New Membranes Coming to Market Performance & Efficiency Lifetime Durability Cost Reduction Innovative Stack Designs High Pressure Electrolysis Performance & Validation Large Scale PEM Electrolyzer Wrap-Up 5

Membrane Development Giner Dimensionally Stable Membranes (DSM TM

incorporated in an engineering plastic support (2D & 3D) Superior

freeze-thaw cycling Stronger Resistance to tear propagation

Membranes optimized for ionomer EW and thickness Enabling

large commercial partner underway Commercial viability in 2015/16

6 Membrane Development Giner Dimensionally Stable Membranes (DSM TM ): High-strength, High-efficiency membranes PFSA ionomer incorporated in an engineering plastic support (2D & 3D) Superior Mechanical Properties No x-y dimensional changes upon wet/dry or freeze-thaw cycling Stronger Resistance to tear propagation Superior to PTFE based supports, 10x stronger base properties Membranes optimized for ionomer EW and thickness Enabling technology for high pressure applications Role to role process with large commercial partner underway Commercial viability in 2015/16 Laser-Drilled Membrane Supports 3D Substrates Chemically Etched R&D funded U.S. Department of Energy Cast 6

0 to 47 kwh e /kg-h 2 @ 1500 ma/cm² MEAs utilize low-loaded catalyst loadings

7 Membrane Efficiency Demonstrated high efficiency DSM membranes in single-cell and large multi-cell stacks Cell voltage efficiency up to 90%(HHV), 44.0 to 47 kwh e /kg-h 1500 ma/cm² MEAs utilize low-loaded catalyst loadings (reduced by 90%) Nafion is a registered trademark of E.I. du Pont Nemours and Company 7

8 Membrane Lifetime Scaled-up Membrane Performance Demonstrated 5,000+ hrs lifetime of scaled-up DSM membrane at 80 C DSM MEA from 5-cell short stack re-assembled into a single-cell stack, total testing time = 5,430 hours Efficiency: up to 88% 1500 ma/cm² Scaled-up testing includes low-cost stack components Membrane Degradation (Estimated Lifetime) F ion Release Rate: 3.7 µg/hr (<10 ppb) DSM -1100EW (Stabilized Ionomer): ~55,000 hours 8

Membrane Durability Performance Under Aggressive Conditions Demonstrated high current density (5,000 ma/cm²) and high pressure (5,000 psig) operation Operated 4-Cell stack at 5,000 ma/cm² for 1,000

9 Membrane Durability Performance Under Aggressive Conditions Demonstrated high current density (5,000 ma/cm²) and high pressure (5,000 psig) operation Operated 4-Cell stack at 5,000 ma/cm² for 1,000 hours DSM operated at 10,000 ma/cm² (in continuous 24 hour test) Membrane Degradation (Estimated Lifetime) Advanced DSM: Improved membrane stability at high operating current density Low degradation enables longer operation at higher temperatures Advanced DSM with proprietary additive mitigates degradation and improves life at high operating current densities 9

10 Stack Efficiency Vs. Cost of H 2 Production Hydrogen production cost dominated by feedstock Feedstock is largest $ contributor Efficiency is key to cost competitiveness! Larger benefit for MW Scale Feedstock H 2 Forecourt Station H 2 Production Cost Component Breakdown 10

11 Giner, Inc. Overview Advancements in Efficiency New Membranes Coming to Market Performance & Efficiency Lifetime Durability Cost Reduction Innovative Stack Designs High Pressure Electrolysis Performance & Validation Large Scale PEM Electrolyzer Wrap-Up 11

Stack Advancements & Cost Reductions 30 to 90 Nm 3 /hr Repeating Cell Unit Fluid End Plate

MEA Cathode Support Mat l Cell Frame (H 2 ) The repeating cell unit comprises 90% of electrolyzer

Reduction Increased active area (2x) Reduced catalyst loadings by 90% Implemented new

60,000 hours Material requirements reduced by 30% Reduced Cathode & Anode Support Mat l

to 10 Parts/Cell-50% labor reduction Commercialized Electrolyzer 1 st to market with 47 kwh/kg

12 Stack Advancements & Cost Reductions 30 to 90 Nm 3 /hr Repeating Cell Unit Fluid End Plate Negative Terminal Positive Terminal End Plate Cell Separator Anode Support Mat l Cell Frame (O 2 ) MEA Cathode Support Mat l Cell Frame (H 2 ) The repeating cell unit comprises 90% of electrolyzer stack cost Part Count Required to Generate 1500 kg- H 2 /day Stack Improvements >60% Stack Cost Reduction Increased active area (2x) Reduced catalyst loadings by 90% Implemented new manufacturing techniques Molded Thermoplastic Components Improved Cell-Separators: Lifetime > 60,000 hours Material requirements reduced by 30% Reduced Cathode & Anode Support Mat l Alternative low cost materials utilized Reduced non-repeater costs >50% Reduced Part Count from 41 to 10 Parts/Cell-50% labor reduction Commercialized Electrolyzer 1 st to market with 47 kwh/kg 1700 ma/cm² Rapid market penetration Product sold in 7 Countries Product exclusively used in renewable energy applications Marked 12

Ambient O 2 Generated directly in PEM Electrolyzer Low maintenance No moving parts No contaminants Cross-cutting

13 Improving Pressure Capabilities of PEM Electrolyzers Advantages of High Pressure PEM Electrolysis Eliminates one or more stages of mechanical compression Reduces system complexity Lower drying requirements Hydrogen at 5,000 psig (350 Bar), Ambient O 2 Generated directly in PEM Electrolyzer Low maintenance No moving parts No contaminants Cross-cutting technology, applicable to Electrochemical Hydrogen Compressors Permits hydrogen generation at user endsite DSM TM Enabling Technology 13

14 High Pressure Electrolyzer Systems Increasing electrolyzer pressure leads to system simplification, but remaining challenges exist: Higher cost BOP components Innovative system component development required Hydrogen dryers Gas-phase separators Level sensing Extended durability testing/validation Full optimization studies Increased back diffusion R&D program initiated to develop new ionomers with reduced gas permeation FCV Home Refueling 14

Validation at National Renewable Energy Laboratory

conditions: 1500-1900 ma/cm² High stack voltage

6 kwh e /kg-h 2 Stack Efficiencies in line with DOE

components Hydrogen drying losses: ~3% (Industry: 10%)

15 Validation at National Renewable Energy Laboratory System Validated at NREL in June 2012 Nominal operating conditions: ma/cm² High stack voltage efficiency: >87% HHV; Energy efficiency;46.6 kwh e /kg-h 2 Stack Efficiencies in line with DOE 2012 Targets Development of low-cost high-efficiency components Hydrogen drying losses: ~3% (Industry: 10%) Giner Stack Efficiency 1500 ma/cm² NREL Report: Milestone (CPS 52066) 15

Electrolyzer Stack Validation Third Party Validation Giner

at multiple sites Customer confirms 2,000 hours at 47 kwh e

BOX in Corsica, France Utilizing GES Low-Cost Electrolyzer

16 Electrolyzer Stack Validation Third Party Validation Giner commercial electrolyzer stack in-use at Areva Site Operating at multiple sites Customer confirms 2,000 hours at 47 kwh e /kg 1,700 ma/cm² AREVA s energy storage platform GREENERGY BOX in Corsica, France Utilizing GES Low-Cost Electrolyzer Stack Modular RFC systems with energy storage from 0.2 to 2MWh 16

17 Giner, Inc. Overview Advancements in Efficiency New Membranes Coming to Market Performance & Efficiency Lifetime Durability Cost Reduction Innovative Stack Designs High Pressure Electrolysis Performance & Validation Large Scale PEM Electrolyzer Wrap-Up 17

18 Large Scale Electrolysis Led by Market Demand Market Drivers U.S. National Defense Authorization Act of FY2007/FY2010: DoD must produce 25% of total energy from renewable energy sources by 2025 European Commission Strategy: 20% share of renewable energy in EU energy consumption, with a 10% share in transport 2050 Roadmap calls for a 55-75% share of RES in gross final energy consumption, 80% reduction in green house emissions 1 Next step: >220 Nm 3 /hr (MW Scale) Nm 3 /hr Target markets require larger electrolyzer stacks and systems Intermittent Renewable Energy Source (RES) integration Backup power for grid outages and load shedding Mobility Power to Gas 0.05 Nm 3 /hr 2-3 Nm 3 /hr Timeline :

MW Scale PEM Electrolysis Increased system

In-house program initiated to develop MW

19 MW Scale PEM Electrolysis Increased system output requires larger stacks to be viable In-house program initiated to develop MW Scale electrolyzer Large scale stacks previously designed and manufactured MW stack design leverages work developed on earlier stacks Reliability, Efficiency, Cost, Single Stack 220+ Nm 3 /hr MW Electrolyzer Stack 19

20 Giner, Inc. Overview Advancements in Efficiency New Membranes Coming to Market Performance & Efficiency Lifetime Durability Cost Reduction Innovative Stack Designs High Pressure Electrolysis Performance & Validation Large Scale PEM Electrolyzer Wrap-Up 20

21 Summary Giner s capabilities continue to grow to meet new market demands Increase efficiency New membrane development High pressure electrolysis stacks & systems Mobility and storage Increased hydrogen output MW scale PEM electrolyzer Efficiency is Key to Competitiveness Giner commercial PEM Electrolyzers exceed market performance High stack efficiencies and improved durability reduce overall operating costs Reduction in Capital Cost achieved by implementing innovate stack designs PEM Electrolysis is a viable technology that is highly cost competitive in large scale applications 21

Thank You! Director of Engineering Monjid Hamdan mhamdan@ginerinc.

22 Thank You! Director of Engineering Monjid Hamdan Director of Business Development Hector Maza Hall 27, D 76/2 22

IV.H Electrolysis. DOE Technology Development Manager: Matt Kauffman Phone: (202) ; Fax: (202) ;

IV.H Electrolysis. DOE Technology Development Manager: Matt Kauffman Phone: (202) ; Fax: (202) ; IV.H Electrolysis IV.H.1 Low-Cost, High-Pressure Hydrogen Generator Cecelia Cropley (Primary Contact), Tim Norman Giner Electrochemical Systems, LLC 89 Rumford Ave. Newton, MA 02466 Phone: (781) 529-0506;