PEM & Alkaline Electrolyzers Bottom-up Manufacturing Cost Analysis

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1 PEM & Alkaline Electrolyzers Bottom-up Manufacturing Cost Analysis Yong Yang Austin Power David Hart E4tech November 10, 2014 Austin Power Engineering LLC 1 Cameron ST Wellesley, MA USA yang.yong@austinpowereng.com E4tech Av. Juste-Olivier Lausanne Switzerland Tel: david.hart@e4tech.com

2 Introduction Objective The objective of the study is to understand the cost reduction potential of the main water electrolysis technologies Water electrolysis could become an important part of future stationary energy and transport systems Where and how it could play a role depends on the cost reduction that could be achieved in moving from a small and unoptimised industry Detailed modelling can provide insight into both ultimately achievable costs and the impact of certain design choices and technology improvements 1

3 Introduction Market Overview Water electrolysis could play a significant role in the future energy system, if predicted cost reductions can be realised. Consolidated views on rollout potential Roadmap for electrolyser deployment by application. Source: 2014 FCH-JU study on water electrolysis Expert predicted cost reductions Data source cost reduction expectations: 2014 FCH-JU study on water electrolysis 2

4 Introduction Market Overview 18% 30% 4% Today s electrolyser market is comparatively small, the industry landscape 18% is 30% highly fragmented and no single design dominates 4% Perhaps 4% of global hydrogen supply is produced via electrolysis Larger (> 50 kw) water electrolysis systems are typically deployed for continuous operation. Examples are fertilisers and methanol production, fats & oils, float glass, The industry is highly fragmented, with a few established players and many start-ups / new entrants and cost reduction potential 30% 30% 18% 48% 18% 48% 4% 4% Coal gasification Electrolysis Natural gas reforming Refinery/Chemical off-gases Coal gasification Electrolysis Natural gas reforming Refinery/Chemical off-gases 48% Coal gasification Electrolysis Coal gasification Natural Electrolysis gas reforming Refinery/Chemical Natural gas reformingoff-gases Refinery/Chemical off-gases Source: IEA (2007) 48% Source: IEA (2007) Chemistry Parameter (Examples) Design philosophy options Implications (Examples) PEM Cell size Small cell versus large cell approach Component material choice, fewer stacks PEM Cell pressure design Balanced versus unbalanced pressure System control, gas purification Alkaline Liquid-gas separators Stack-internal versus external Cell material usage efficiency Alkaline Operational pressure Pressurised versus unpressurised design Cell material choices, gas purification 3

5 Introduction Technology Overview Overview of key performance indicator of state-of-the-art electrolyser technology. Parameter Unit Commercial alkaline Commercial PEM Stack capacity kw 200 4, System capacity kw 1,100 5, ,200 Specific electricity input (system, nominal load) kwh/kg H Hydrogen output pressure bar(g) Stack lifetime (continuous operation) hours 60,000 90,000 20,000 60,000* System lifetime (continuous operation) years Current density A/cm² Overload ability % el Currently not more than 20% offered commercially, though PEM could ultimately have 200% 300% Operating temperature C Minimum part load % el Specific electricity input (system, variable load) kwh/kg H2 No manufacturer data available. At stack level specific electricity may reduce by 2 to 5 kwh/kg at 50% of nominal electric load Responsiveness (ramp time) % el /second Start-up time cold & pressurised / cold & unpressurised >20 minutes / several hours ~5 / ~15 minutes 4

6 Total Cost of Owership ($) Approach Manufacturing Cost Modeling Methodology This approach has been used successfully for estimating the cost of various technologies for commercial clients and the DOE. Technology Assessment Manufacturing Cost Model Scenario Analyses Verification & Validation Literature research Definition of system and component diagrams Size components Develop bill-ofmaterials (BOM) Define system value chain Quote off-shelve parts and materials Select materials Develop processes Assembly bottom-up cost model Develop baseline costs Technology scenarios Sensitivity analysis Economies of Scale Supply chain & manufacturing system optimization Life cycle cost analysis Cost model internal verification reviews Discussion with technical developers Presentations to project and industrial partners Audition by independent reviewers 100% 100% Pt 99.9% 98.5% Anode Ink 100% 100% Purchased GDL Anode Side Catalyst Layer 99% 98.5% 100% 98.5% 80,000 70,000 60,000 50,000 PEMFC Plug Hybrid Vehicle Full Battery Electric Vehicle 6.3% Balance of Stack 2.4% Seal 8.4% Stack Assembly Stack Conditioning 2.7% Membrane 8.0% 100% 100% 100% 100% Nafion Ionomer Pt 99% 98.5% Cathode Ink 99.9% 98.5% Membrane Processes 99% 98.5% Cathode Side Catalyst Layer Hot Press Lamination 40,000 30,000 20,000 10,000 Bipolar Plate 26.1% Electrode 41.0% Purchased GDL 100% 100% 0 3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO GDL 5.1% 5

7 Air (POX only) Nat. Gas Water NG line in To Vehicle Fuel Reformer H2 High Pressure Cascade Storage System CNG High Pressure Cascade Storage System Electrolyzer or SMR, High-Pressure Compressor Heat Catalytic Burner H 2 -rich gas Dispenser Security Fence H 2 -poor gas PSA 99.99% pure H 2 Underground Piping with shared conduit Fire Detector Covered Fueling Island Property of: TIAX LLC 1061 De Anza Blvd. Cupertino, CA Low Pressure Storage Flow cntrlr Fuel Station Perimeter Gaseous Fuel Dispensing Islands Task 5 CNG/Hydrogen Fueling 10 ft Vent Compressor with intercoolers Medium Pressure Storage Flow cntrlr Building Hydrogen and CNG fueling station High Pressure Storage Flow cntrlr SIZE DWG BY DWG NO REV A Stefan Unnasch B S SCALE 1" = 8 ft 5 Jan 2004 SHEET 1 OF 1 Minimum set-back distances for hydrogen and/or natural gas storage (more stringent gas noted if relevant) Walls with minimum fire rating of 2 hours 5 ft ft Wall openings (doors & windows) 25 ft ft Building intake vents 50 ft ft Adjoining property that can be built on 10 ft ft Public sidewalks, parked vehicles 15 ft ft Streets 10 ft ft Railroad tracks 15 ft ft Other flammable gas storage 10 ft ft Cooling Tower Cold Water Anode Powder Prep Tape Cast Slip Cast Electrolyte Small Powder Prep Vacuum Plasma Spray Screen Print Slurry Spray Blanking / Slicing Sinter in Air 1400C Forming of Interconnect QC Leak Check Shear Interconnect Cathode Small Powder Prep Screen Print Vacuum Plasma Spray Slurry Spray Paint Braze onto Interconnect Sinter in Air Braze Finish Edges Wafer Cost ($) Total Cost of Owership ($) Approach Manufacturing Cost Modeling Methodology Combining performance and cost model will easily generate cost results, even when varying the design inputs. Conceptual Design Process Simulation Process Cost Calcs $10 $9 $8 Material Process $7 $6 CO 2 H 2 O $5 $4 $3 $2 $1 $0 Lapping CMP Wet thermal Oxidation Spin Coating Wet Etching SiO2 DC Sputtering Ni RF Sputtering E Spin Coating Stepper DC Sputtering Ag Stripping Spin Coating Stepper Dry Etching SiO2 DRIE Si Wet Etching SiO2 Dry Etching NI System layout and equipment requirements Energy requirements Equipment size/ specs Process cost Material cost Site Plans Capital Cost Estimates Product Costs Interconnect 80,000 70,000 PEMFC Plug Hybrid Vehicle Full Battery Electric Vehicle 60,000 Anode Electrolyte Cathode 50,000 Fabrication 40,000 30,000 20,000 Site Plan - Fueling Station Note: Alternative production processes appear in gray to the bottom of actual production processes assumed Stack Assembly 10, Year TCO 5-Year TCO 10-Year TCO 15-Year TCO Safety equipment, site prep, land costs High and low volume equipment costs Product cost (capital, O&M, etc.) 6

8 Approach Manufacturing Cost Structure Austin Power Engineering s manufacturing cost models can be used to determine a fully loaded selling price to consumers at high or low volumes. Corporate Expenses Research and Development Sales and Marketing General & Administration Warranty Taxes Profit Sales Expense General Expense Consumer Selling Price Fixed Costs Equipment and Plant Depreciation Tooling Amortization Equipment Maintenance Utilities Building Indirect Labor Cost of capital Overhead Labor Factory Expense Direct Labor Manufacturing Cost Variable Costs Manufactured Materials Purchased Materials Fabrication Labor Assembly Labor Indirect Materials Direct Materials We assume 100% financing with an annual discount rate of 10%, a 10-year equipment life, a 25-year building life, and three months working capital YY 7

9 Approach Scope Our cost assessment includes four systems which are a current alkaline system, a future alkaline system, a current PEM system, and a future PEM system. Alkaline PEM Future Future Alkaline System Future PEM System Current Current Alkaline System Current PEM System 8

10 Alkaline System Alkaline systems are assumed to have the following system and stack designs in the different scenarios. Alkaline Unit Small Cell Current Large Cell Future System size kw 1,000 4,000 Stack size kw 250 2,000 Stacks per system 4 2 System Pressure Barg H2 Purity % % % Active cell area cm² 3,125 12,500 Cell voltage V Active area / total cell area (Gas/liquid separation) % 25 (internal) 85 (external) Current density A/cm² Membrane material polyantimonic acid / polysulfone Zirfon Anode / cathode material Ni foam (plus Ni(OH)2) / Ni mesh Ni foam (plus Ni(OH)2) / Ni mesh Conductive porous layer Ni foam Ni foam Cell frame material PPO Polymer SS316 Annual Production Volume 12 MW 1.2 GW 9

11 Alkaline System Stacks Example detail: Alkaline electrolyzer stacks repeat components section view Repeat cell components Repeat cell components Anode conductive layer Anode Anode conductive layer Anode Membrane Cathode Cathode conductive layer Bipolar plate Cell frame Cell Gasket Membrane Cathode Cathode conductive layer Bipolar plate Cell frame Cell Gasket Current Internal Gas/Liquid Separation Electrolyzer Future external Gas/Liquid Separation Electrolyzer Based on patent information and other data 10

12 Alkaline System Stack Costs Current alkaline electrolyzer stack costs approximately $435/kW and future alkaline electrolyzer stack costs about $101/kW. Current Alkaline Stack Cost $435/kW Future Alkaline Stack Cost $101/kW 8% 3% 0% Anode 3% 3% 10% Anode foam 3% Electrolyte 4% 4% Cathode foam Cathode Cell Frame 17% Bipolar Plates Gaskets 1% 0% 2% 1% 1% 4% 3% 17% 9% 5% 18% Anode Anode foam Electrolyte Cathode foam Cathode Cell Frame Bipolar Plates Gaskets End Plates End Plates 19% 15% 7% 4% Current Collector Insulator Frame Tie Bolts Final Assy 28% 6% 5% Current Collector Insulator Frame Tie Bolts Final Assy 11

13 Alkaline System System Costs Current alkaline electrolyzer system costs about $1,072/kW and future alkaline electrolyzer system costs about $494/kW. Current Alkaline System Cost $1,072/kW Future Alkaline System Cost $494/kW 1% 2% 2% 5% 5% 1% 3% 1% 1% 3% 7% 33% 41% Stack HV power supply module System control unit De-oxygen unit Dryer unit Electrolyte cooling unit Chiller Water treatment unit Gas & water loops Others & Assembly, Test 1% 11% 7% 1% 4% 50% 21% Stack HV power supply module System control unit De-oxygen unit Dryer unit Electrolyte cooling unit Chiller Water treatment unit Gas & water loops Others & Assembly, Test 12

14 Alkaline System Cost Analysis In Alkaline stacks, higher current densities are key to reducing costs, but all options are subject to fundamental limits. Cost contributors Pathways to cost reduction Identified limits Cell frame, bipolar plate, membrane, electrodes Cell frame Gas/liquid separation Cell frames made of (expensive) machined SS316 with polymer coating Increase current density and reduce materials use through innovative component design and advanced electrode materials Reduce material use through large cell concepts with a better ratio between active area and frame area Reduce the amount of frame material required through use of external gas separators Replace by (cheaper) injection moulded polypropylene, though mechanical stability at pressure may be limited Industry reports 0.8 to 1.0 A/cm² as a long term target. Limitation is acceptable efficiency at high currents. (Current density today: 0.4 A/cm²) Mechanical stability of cell components, depending on stack pressure level Increase active area from ~25% to ~75% of frame area. Manifold area as limiting factor. Mechanical stability of polypropylene 13

15 PEM System PEM systems have the characteristics below: PEM Unit Small Cell Current Large Cell Future System size kw 180 4,000 Stack size kw 60 1,000 Stacks per system 3 4 System Pressure Barg H2 Purity % % % Active cell area cm² 210 1,905 Active area / total cell area % Current density A/cm² Membrane material Nafion 200µm Nafion 200µm Catalyst loading mg/cm² 4.0 Pt 0.1 Pt, 0.3 Ir Conductive porous layer Ti foam Ti foam Screen pack plates Three layer Ti mesh Function replaced by flow field plates Bipolar plate Ti foil SS316 with Ti coating Cell frame material Ti SS316 Annual Production Volume 3 MW 1.2 GW 14

16 PEM System Stack Costs Current PEM electrolyzer stack costs approximately $1,144/kW and future PEM electrolyzer stack costs about $87/kW. Current PEM Stack Cost $1,144/kW Future PEM Stack Cost $87/kW 0% 2% 13% 0% 7% 10% Anode Electrolyte Cathode MEA Gasket 1% 1% 1% 3% 1% 3% 2% 18% Anode Electrolyte Cathode MEA Gasket 1% 3% 10% Conductive Porous Plate Screen Pack Pressure Pad Separator Plate Pressure Pad 17% 1% 1% Conductive Porous Plate Screen Pack Pressure Pad Separator Plate Pressure Pad Cell Separator Plate Cell Separator Plate 21% 6% 3% Cell Frame Gaskets End Plates Current Collector 17% 27% Cell Frame Gaskets End Plates Current Collector 3% 3% 3% 16% Insulator Tie Bolts Final Assy, Conditioning, Test 3% 4% 0% Insulator Tie Bolts Final Assy, Conditioning, Test 15

17 PEM System System Costs Current PEM electrolyzer system costs about $2,013/kW and future PEM electrolyzer system costs about $441/kW. Current PEM System Cost $2,013/kW Future PEM System Cost $441/kW 2% 2% 2% 11% 17% 4% 3% 4% Stack HV power supply module System control unit Feed water treatment Chiller 57% Dryer Gas & water loops Others & Assembly, Test 1% 4% 2% 13% 2% 20% Stack HV power supply module System control unit Feed water treatment Chiller Dryer Gas & water loops Others & Assembly, Test 56% 16

18 PEM System Cost Analysis PEM cost reduction opportunities are strongly related to the reduced use of titanium, though other components contribute. Cost contributors Pathways to cost reduction Identified limits Components made of titanium (cell frame, screen pack, porous plate) Electrode catalysts Supplied membrane Reduce use of titanium in components, e.g. make cell frames of steel plus coatings instead of full machined titanium; Make bi-polar plates of steel plus titanium coating instead of full titanium. Increase current density. Material changes using advanced catalyst support structures, mixed metal oxides and nano-structured catalysts. High volume orders and/or dedicated production Titanium (high material and processing cost) expected to remain as the material of choice for acidic electrolysers Precious metal cost and catalyst activity for acceptable efficiency. Goals are: - 0.3mg/cm² Iridium - Anode - 0.1mg/cm² Pt - Cathode Costly fluorine chemistry in Nafion production 17

19 Conclusions Expert-predicted cost reductions seem plausible and could make electrolysis much more competitive Alkaline cost reduction is quite sensitive to volume production and increased current density PEM routes to cost reduction include volume production, system scale-up, reduction of expensive materials, and increased current density PEM is less mature so future cost is sensitive to a number of uncertain technology development assumptions BoP costs (mainly power supply) start to dominate at high production volumes Cost reduction and increased deployment will have to go hand-in-hand for the industry to achieve aggressive targets Other technology may be interesting to analyse, for example SOEC 18

20 Thank You! Contact: Yong Yang Austin Power Engineering LLC 1 Cameron St Wellesley MA USA Tel: yang.yong@austinpowereng.com Contact: David Hart E4tech Av. Juste-Olivier Lausanne Switzerland Tel: david.hart@e4tech.com 19

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