Recent Advances in Cost & Efficiency for PEM Electrolysis Everett Anderson Technical Forum 25 April 2012 Proton, Proton OnSite, Proton Energy Systems, the Proton design, StableFlow, StableFlow Hydrogen Control System and design, HOGEN, and FuelGen are trademarks or registered trademarks of Proton Energy Systems, Inc. Any other brands and/or names used herein are the property of their respective owners.
Outline Introduction Markets Industrial & Energy Improvements Cost & Efficiency i Development Scale-up & Higher Pressure Other Developments Electrochemical Compression Alkaline Exchange Membranes Summary 2
Key Takeaways for Today Hydrogen markets exist today that can leverage advancements in on-site generation technologies PEM electrolysis is already highly cost competitive in these markets PEM electrolysis is reaching alkaline output capacities and has performance advantages for many applications Electrolysis demonstrated for fueling and can help bridge the infrastructure gap Hydrogen is an attractive option for renewable energy storage There are clear pathways for considerable cost reductions and efficiency improvements 3
Proton s Markets, Products & Capabilities Power Plants Complete product Heat Treating development, manufacturing & testing Turnkey product installation Semiconductors World-wide sales and service Laboratories Containerization and hydrogen storage solutions Government Integration of electrolysis into RFC systems 2000: S-Series 1-2 kg/day 13 bar 2006: HPEM 0.5 kg/day 138 bar 2009: Outdoor HPEM 2 kg/day 165 bar 2011: C-Series 65 kg/day, 30 bar Steady History of Product Introduction 2003: 2006: 1999: GC 300-600 H-Series StableFlow ml/min 4-12 kg/day Hydrogen 13 bar 30 bar Control System 2010: Lab Line 4
Industrial Hydrogen Markets Hydrogen is a fast growing industrial gas Major industrial gas consuming industries: - Power Plants/Electric Power Generator Cooling Over 18,000 hydrogen-cooled generators world-wide Addressable market estimated at over $2 billion Improved plant efficiency and output/reduced greenhouse gas emissions Payback typically less than one year - Semiconductor manufacturing - Flat panel computer and TV screens - Heat treating - Analytical chemistry (carrier gases for GC, etc.) 5
Typical Power Plant Implementation Environmental Benefits: Pollution reduction 1 ton of CO 2 for every MW/hr improvement Based on improvement from 95% to 99% H 2 purity 6
Hydrogen Energy Markets Fueling Backup Power Telecom Remote sites Renewable Energy Capture Regenerative Fuel Cell System 7
Hydrogen Fueling: >20 stations worldwide 8
H 2 Generation: Proton s HOGEN C-Series 30 Nm 3 /h (65 kg/day) H 2 packaged gas generation system Compliant with ISO 22734-1 water electrolyzer standard PEM cell stack delivers 30 barg, +99.9995% 9995% pure H2; 1 bar O2 HOGEN industrial version, FuelGen option Factory matched cooling, water conditioning, container Platform for near-term, renewable-based fueling stations Page 9
PEM Technology: Fuel Cell vs. Electrolyzer Similar materials of construction: PFSA membranes, noble metal catalysts Electrolysis membrane is fully hydrated, no RH cycling concerns Have to withstand high pressure differential (200-2400 psi) and high sealing loads Electrolysis stack materials have to withstand ~2V potentials particular concern for O 2 catalyst and flow fields Longer lifetime expectations (competing with gas cylinders) 10
Current Stack Limitations Efficiency driven by: Membrane resistance Oxygen overpotential Cost driven by: Membrane electrode assembly Flow fields/separators 32% 15% System 53% % Overpotential 60% 50% 40% 30% 20% 10% Activation and Ohmic Overpotentials Cathode Activation Anode Activation Ionic Electronic 0% 0 500 1000 1500 2000 2500 48% 25% 3% 5% 13% 24% 12% 23% Stack Current Density, ma/cm2 Power supplies Balance of plant MEA flow fields and separators bl balance of cell balance of stack Page 11
Technology Roadmaps Detailed product development pathways laid out internally Balance of plant scale up Cell stack cost and efficiency i Product improvements and introductions Balanced portfolio of near and long term implementation Executing on funded programs to address each area % Baseline e cost 100% 80% 60% 40% 20% 0% MEA Balance of cell Balance of stack Current <1 year 1 3 years >3 years Implementation Timeline Page 12
Cell Stack Needs 30% reduction in membrane thickness Order-of-magnitude reduction in catalyst loading Automation of MEA fabrication for electrolysisspecific MEAs Online quality control measurements 50% reduction in bipolar assembly cost Reduction of metal content in bipolar assembly Reduction in bipolar assembly process time Increased part yield from suppliers Page 13
Collaboration Strategy Leverage key competencies of component suppliers, integrators, universities, and national labs 14
Electrolysis Membranes Typically 170-250 microns thick versus 25-50 microns for fuel cells Need reinforcement to withstand high pressures Durability requirements make qualification AMPS8_TRND challenging 2500 Accelerated testing: combination of pressure, voltage, and temperature cycling (asf) Current Density ( 2000 1500 1000 500 H2PRES8_TRND 3000 2500 2000 1500 1000 500 Pressure (PSIG G) 0 0 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 Time Minutes (min) Page 15
Efficiency Needs and Progress: Membrane Reduce Membrane Thickness Increase Operating Temperature 2.7 2.6 2.5 2.4 2.3 Approximate current production range Potential (V) 2.2 2.1 2 19 1.9 1.8 New membrane enables 2x current 90 micron (3.6 mil) 60 micron (2.4 mil) 1.7 1.6 1.5 1.4 Advanced membranes show high efficiency while maintaining durability at 80C 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 Current Density (A/cm 2 ) Page 16
Electrolysis Catalysts Pt not a good O 2 evolution catalyst Oxygen reaction is ~70,000 times slower than hydrogen reaction Highest activity catalysts are not stable in acid environment 3.6 Strategy: evaluate 3.2 mixed metals to obtain 2.8 stability and activity it 2.4 characteristics / volts Cell potential / 2.0 1.6 PEM Electrolysis Endurance Testing O 2 Evolution Catalyst Evaluation 200 psi H 2 /0 psi O 2, 1.8 A/cm 2, 50 C Iridium Oxide Ruthenium Oxide 0 100 200 300 400 500 600 Run time / hrs Page 17
Efficiency Needs and Progress: Catalyst Oxygen reaction is ~70,000 times slower than hydrogen reaction Progress shown is approximately factor of 20 improvement ial (V) Cell Potent 2.050 2.000 1.950 1.900 1.850 1.800 Baseline M 1 xm 2 1-x M 1 xm 2 1-x M 1 xm 2 1-x } } Annealed Adv Process Annealed Adv Process Non-Annealed New catalyst blend New synthesis conditions; anode catalyst ink 1.750 0 100 200 300 400 500 Run Time (hours) Combinatorial approach initiated with U. Wyoming Partnership with 3M to manufacture NSTF electrodes 18
Cost Needs and Progress - Catalyst Demonstrated new 2.20 alternative application 2.00 techniques 1.80 1.60 Step 1: 55% reduction on 1.40 anode 1.20 1.00 Step 2: >90% reduction on cathode Cell Poten ntial (V) 2.2 2 Catalyst Loading Test: 1800 ma/cm2, 80oC Baseline 20% loading reduction 55% loading reduction 0 100 200 300 400 500 Run Time (hours) 80ºC operation 3M nanostructured thin film electrode Potential (Volts) 1.8 1.6 1.4 1.2 3M Cathode #1, 8 mil total 3M Cathode #2, 8 mil total Proton Baseline, 7 mil 1 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Current tdensity (Amps/cm2) 19
Progress to Date: Catalyst Loading Loading % Catalyst 100% 90% 80% 70% 60% 50% 40% 30% 0% Implemented: 25% reduction Qualified: Next gen cathode process Feasibility Demonstrated: t Next gen anode, NSTF cathode 20% Goal: NSTF anode and cathode 10% Baseline Internally funded Internally funded DOE Step 1 DOE Step 2 End Goal Implementation Timeline 20
Cost Needs and Progress: Flow Fields New cathode flow field: 12% cost savings/stack Next Phase: New bipolar assembly concept, 50% metal reduction Nitride coatings: eliminates process steps and mitigates hydrogen embrittlement 21
Progress to Date: Flow Field Cost % Bi ipolar Asse embly Cost 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Implemented: Improved Frame Feasibility Demonstrated Baseline DOE Step 1 DOE Step 2 End Goal Implementation Timeline Page 22
Efficiency Improvements Potentia al (Volts) 2.4 Technology Progression 2.3 Baseline, 50C Advanced Oxygen Catalyst, 50C 2.2 Advanced membrane, 80C Advanced cell design, 80C 2.1 2 19 1.9 1.8 1.7 1.6 1.5 Current Stack (~70% Eff (HHV) Advanced Stack (>86% Eff (HHV) 1.4 0 0.5 1 1.5 2 2.5 3 CurrentDensity (A/cm2) 23
Electrolysis System Development From Single to Multi-Stack Systems Up to three stacks per system HOGEN GC HOGEN S Series HOGEN H Series HOGEN C Series 24
Increased System Output Led By Larger Stack Development 28 cm 2 0.05 Nm 3 /hr 0.01 kg/day Commercial 86 cm 2 210 cm 2 550 cm 2 1100 cm 2 2 Nm 3 /hr 10 Nm 3 /hr 30 Nm 3 /hr 90 Nm 3 /hr Commercial Commercial Pre Production Concept 25
550 cm 2 Stack Development Improvement in bipolar plate design Current 86 cm 2 design tested to over 2.4 1 million cell hours 2.3 2.2 CFD modeling shows more uniform flow 2.1 Demonstrated operation up to 30 bar >15,000 hours validated d on 3-cell > 1,000 hours on 10-cell stack Full-scale +50 kg/day stack scale-up in process l Potential (V) Cell 2.5 2.0 1.9 1.8 17 1.7 1.6 1.5 0.6 SQFT- 3 Cells (1032 amps, 425 psi, 50 C) Cell ll1 Cell ll2 Cell ll3 0 2500 5000 7500 10000 12500 15000 Run Time (hours) 26
Resulting Hydrogen Cost Progression $10 $8 Based on $0.05/kWh electricity odel $/kg H2 2, H2A m $6 $4 $2 DOE 2012 Target DOE 2017 Target $ 65 kg/day 200 kg/day system, pre production 200 kg/day system, full production* *Assumes volumes of 500 units/year 27
Small-Scale High Pressure Generation Proton s Proven Platform Pressurized H 2, Ambient O 2 Indoor & Outdoor Versions 193 bar H 2 Stack Also Developed HOGEN S-Series 13 bar H 2, 260 to 1050 NL/hr 240 Single Phase Power +10 Year History, 100 s Shipped 3.0 Proton Energy Systems In-House Cell Stack Endurance Testing HOGEN HPEM 165 bar H 2, 260 to 1050 NL/hr Early Production, Multiple Shipments Aver rage Cell Potential (Volts, 50 o C) 2.6 2.2 1.8 25-cell stack 200 psig (13 barg) 1200 ASF (1.3 A/cm 2 ) 4 µv/cell hr Decay Rate >60,000 000 hr @ 13 bar 1.4 0 10,000 20,000 30,000 40,000 50,000 60,000 Operating Time (Hours) 20,000 hr @ 165 bar 28
HOGEN NF Small-Scale 700 bar psi Fueler Electrochemical compression to 165 bar, 2.2 kg/day production 700 bar psi slow-fill fueling capability Qualified for GM vehicle fueling Electrolyzer and Electronics Compression CONCEPT 3 hp single-stage 700 bar boost compressor Storage FABRICATION High pressure electrolyzer Outdoor-rated 2.2 kg/day Medium Pressure Storage 165 bar psi 9 kg Simple dispensing interface Packaged system boundary Vehicle Fill 4 kg at up to 700 bar Slow fill INSTALLATION 29
Higher Pressure Development: 350 bar Proton s Current Development Highe est Sealing Pressur re 350 bar Cell Stack Up to 1050 NL/hr Prototype Design Completed 350 bar Test System Design Completed Fabrication Underway Operational Test by Year-End 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 Successful Sealing to >525 bar * * * * Design Concept 1 *unacceptable MEA damage * * * * Design Concept 2 1 1.5 1.76 2 1 1.5 1.76 1.88 2 1 1.24 1.5 2 1 2 2.4 2.8 3 Normalized Load 350 Bar Home Fueler Concept 30
Electrochemical H 2 Compression Past experience in EHC design/testing Based on PEM electrolysis Recently tested new cell architecture Internal humidification Thin membrane seal capability 2.3 22 2.2 2400 PSI, 118 F, 1000 h 1100 PSI, 115 F, 1000 h 200 PSI, 113 F, 1000 h RND0616001 I-V Performance @ 1000 hr Versus Pressure 1.2 Electrochemical Compressor Cell Configuration Comparison, 70 C Baseline Config 2.1 1.0 Alt Membrane 1 Alt Membrane 2 ntial (Volts) 2.0 (V) 0.8 Adv Config No Humidification Average Cell Pote 1.9 1.8 Potential ( 0.6 0.4 1.7 02 0.2 1.6 1.5 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Current Density (A/cm 2 ) 0.0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Current Density (A/cm2) 31
AEM Electrolysis Cell Membrane are RFCs highly efficient Alkaline environment enables elimination of most expensive components New materials increasing durability O 2 + 4H + Anode 2H 2 O 4e H + Acid 2H 2 Cathode 4H + O 2 + 2H 2 O Anode 4OH 4e 2H 2 + 4OH OH 2e Cathode 2H 2 O Alkaline $100,000 Acid Liquid vs. Membrane voltage losses Raw Ma aterial $/lb $10,000 $1,000 $100 $10 $1 Alkaline Acid Alkaline Platinum Iridium Nickel Titanium Stainless Catalyst Material Flow fields 32
AEM Electrolysis Accomplishments Newly developed membranes/ionomers showing stability improvement vs. commercial alkaline exchange materials Low cost flow field Progression of MEA Performance Over Year 1 Process Improvement 3 materials validated System concept design and BOM completed 2 Continuing work on 1.9 1.8 performance and 1.7 1.6 1.5 stability 0 Op perating Potential (V) 2.9 2.8 2.7 2.6 2.5 2.4 2.3 2.2 2.1 Dec 10 Jan 11 Aug 11 Aug 11 Sep 11 Target Potential 1.8 V @ 500 ma/cm 2 100 200 300 400 500 600 700 800 900 1000 Current Density (ma/cm 2 ) 33
Summary Proton s capabilities continue to grow at a rapid pace Increased hydrogen capacity Increased operating pressure Increased efficiency Efficiency targets enabled by further cost reduction for operation at lower current density Continuing advancements rely on scale up and processing, not new science invention Leveraging today s commercial markets in preparation for tomorrow s energy applications 34
Thank you! Everett Anderson eanderson@protononsite.com +1 203 678 2105 www.protononsite.com 35