Manufacturing Competitiveness Analysis for PEM and ...

1 CEMAC Clean Energy Manufacturing Analysis Center 1 Manufacturing Competitiveness Analysis for PEM and Alkaline Water Electrolysis SystemsMark Ruth (Presenter),Ahmad Mayyas, and Maggie Mann National Renewable Energy LaboratoryFuel Cell Seminar and Energy Expo11/08/2017 CEMAC Clean Energy Manufacturing Analysis Center 2 AgendaIntroductionPEM Electrolyzer - Functional Specs & System DesignAlkaline - Functional Specs & System DesignCost Analysis for PEM and Alkaline ElectrolyzerConcluding Clean Energy Manufacturing Analysis Center 3 IntroductionICEMAC Clean Energy Manufacturing Analysis Center 4 Motivation: Infrastructure for Vehicles 2020 sales/production estimate >30,000 FCEVs 2030 sales/production estimates >250,000 FCEVs on roads Is hydrogen infrastructure ready to support this number of FCEVs?

2 Source: UkH2 MobilityCEMAC Clean Energy Manufacturing Analysis Center 5 Comparison between PEM and Alkaline ElectrolyzersCharacteristicsAlkalinePEMU nitNotesCurrent - - Temperature60 8050 84 CElectricity Consumption(Median)50 73 (53)47 73 (52)kWh/kg-H2 Electrolysis system only. Excluding storage, compression and dispensingMin. Load20 - 40%3 10%Startup Time from Cold to Min. Load20 min - 60+5 15minutesSystem Efficiency (LHV)(Median)45-67%(63%)45 71%(63%)System Lifetime(Median)20-30(26)10-30(22)Ye a rSystem Price$760 $1,100($930)$1,200-$1,940($1,570)Includi ng power supply, system control and gas drying. Excluding grid connection, external compression, external purification and H2storageSources of data: Bertuccioliet al.

3 , 2014, NREL 2017 CEMAC Clean Energy Manufacturing Analysis Center 6 PEM Electrolyzer - Functional Specs & System DesignIICEMAC Clean Energy Manufacturing Analysis Center 7 Oxygen/ Water Phase SeparatorHeat ExchangerElectrolyzerStackWater/H2 SeparatorPumpCity WaterDryerH2 Low Pressure StorageTransformerRectifierHigh Voltage SupplyPEM Electrolyzer System DesignBack Pressure RegulatorH2H2 OControllable ValveO2DI WaterWater CleanerCombustible Gas DetectorHot WaterDemisterDemister* Stack components picture from = Porous Transport LayerCEMAC Clean Energy Manufacturing Analysis Center 8 Derived Functional SpecificationsPartAssumptionsNotesMembra neNafion117 (Purchased)PFSA (PEEK, PBI)PtPt -price= 1500/t r.

4 O zDOE Current valueCCMS pray CoatingPlatinum loadings: Anode= 7g/m2 (Pt)Cathode= 4g/m2 (Pt-Ir )Porous Transport Layer Sintered porous titaniumTi-price= $ printed PPS-40GF or PEEK sealSeal: cm from each side for MEA bondingPlatesStainless steel 316 LCoated(plasma Nitriding)Stack Power1020501002005001,0002,0005,00010,00 0kWsingle cell ampsAcurrent densityA/cm2reference voltageVpower densityW/cm2Pt-Ir loading- Anode g/m2 PGM loading Cathode g/m2single cell powerWCells per system5102550101252505101025245048cellss tacks per system111111241020stackscells per Clean Energy Manufacturing Analysis Center 9 Alkaline Electrolyzer - Functional Specs & System DesignIIICEMAC Clean Energy Manufacturing Analysis Center 10 Phase SeparatorHeat ExchangerAlkaline Electrolyzer StackPhase SeparatorPumpCity WaterDryerH2 Low Pressure StorageTransformerRectifierHigh Voltage SupplyAlkaline Electrolyzer SystemBack Pressure RegulatorH2H2O+ KOHC ontrollable ValveO2 KOH + H2 OWater CleanerCombustible Gas DetectorDemisterDemisterO2 +

5 H2O + KOHH2 + H2O + KOHH2O + KOHH2O + KOHE lectrolyte Flow DirectionFlow DirectionFlow DirectionFlow DirectionCEMAC Clean Energy Manufacturing Analysis Center 11 System rated power1020501002005001,0002,0005,00010,00 0kWElectrolyteSingle cell amps150150150150150150300300300300 ACurrent cell per system40801993977941,9851,9853,9699,9211 9,842cellsStacks per system1122410102050100stackscells per stack4080100199199199199199199199cellsH2 O+ 30% KOHH2O+ 30% KOHA lkaline Electrolyzer - Functional SpecsPartMaterialsNotesMembranem-PBICast membrane using doctor-blade machineElectrodesRaney-nickelPVD +Leaching to get the required porosityPorous Transport Layer PureNickel SheetsCorrosion resistance in alkaline solutionFramePPS-40GF or PEEKI njection moldingPlatesNickel platesSurface treatment of high purity sheetsArea DoubledPVD.

6 Physical vapor depositionCEMAC Clean Energy Manufacturing Analysis Center 12 Cost Analysis for PEM and Alkaline ElectrolyzerIVCEMAC Clean Energy Manufacturing Analysis Center 13 PEM - Bipolar PlateCoil - Stainless Steel 316 LBlankingStampingCleaning (Chemical Bath)CleansingPlasma NitridingN2 Gas + High Voltage and TemperaturePlasma NitridingFurnaceFinal PlateCase Hardening (Nitriding)CEMAC Clean Energy Manufacturing Analysis Center 14 PEM Stack Assembly Semi-Automatic assembly line 3 workers/line PPS-40GF Adhesive Materials for MEA Compression bands or tie rods Stainless steel 316L end plates (thickness 30 mm)Image from: Mayyas et al., 2016 CEMAC Clean Energy Manufacturing Analysis Center 15 PEM Stack Assembly65 kg H2/day385 kg H2/dayCEMAC Clean Energy Manufacturing Analysis Center 16 Alkaline - Raney Nickel ElectrodesProcess Flow DiagramNi-SheetsThickness = mmDegreasingPVDArSputteringTo remove NiOfrom the surfaceLeaching1% NaOHLeaching10% NaOH2 hr@RT20 hr@RTLeaching10% NaOH4 hr@100 CLeaching can be made in one step with longer time and higher concentration of NaOH(~30%)Based on Kjartansdo ttiret al.

7 , 2013 Electrode AssemblyMembraneImage from Chadeet al., 2013 CEMAC Clean Energy Manufacturing Analysis Center 17 Alkaline - Raney Nickel ElectrodesPreliminaryPreliminaryCEMAC Clean Energy Manufacturing Analysis Center 18 Manufacturing Cost of Electrolyzer Stacks Alkaline electrolyzer stacks have larger cost in $/kg-H2 Cost curve for a 200kW systemA comparative cost Analysis between PEM and alkaline stacks using hydrogen production rates (not the cost of making hydrogen from the electrolyzers)CEMAC Clean Energy Manufacturing Analysis Center 19 Manufacturing Cost of Electrolyzer Stacks Alkaline electrolyzer stacks have larger cost in $/kg-H2 basis Cost curve for a 1MW systemA comparative cost Analysis between PEM and alkaline stacks using hydrogen production rates (not the cost of making hydrogen from the electrolyzers)CEMAC Clean Energy Manufacturing Analysis Center 20 Concluding RemarksVCEMAC Clean Energy Manufacturing Analysis Center 21 Conclusions Alkaline water electrolyzershave lower current and power densities, but have lower initial cost (per kW basis) PEM electrolyzersmayhave lower stack cost in ($ per Nm3/hr)

8 Good similarities in Manufacturing processes for PEM and alkaline electrolysis ( , membrane casting, plates stamping & coating, end plates, stack assembly, etc.)CEMAC Clean Energy Manufacturing Analysis Center 22 Questions?Mark Clean Energy Manufacturing Analysis Center 23 THANK YOU!This work was authored by the National Renewable Energy Laboratory, operated by Alliance for Sustainable Energy, LLC, for the Department of Energy (DOE) under Contract No. DE-AC36-08GO28308. Funding provided by the Department of Energy Office of Energy Efficiency and Renewable Energy fuel Cell Technologies Office. The views expressed in the article do not necessarily represent the views of the DOE or the Government.

9 The Government retains and the publisher, by accepting the article for publication, acknowledges that the Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government Clean Energy Manufacturing Analysis Center 24 Backup SlidesCEMAC Clean Energy Manufacturing Analysis Center 25 FCEV 2015-2024 CEMAC Clean Energy Manufacturing Analysis Center 26 International Manufacturer of Onsite Hydrogen Production SystemThis map can be accessed from Clean Energy Manufacturing Analysis Center 27 PEM ElectrolysisCEMAC Clean Energy Manufacturing Analysis Center 28 PEM - Functional SpecificationsManufacturerHydrogenicsHyd rogenicsProton OnSiteProton OnSiteProton OnSiteProton OnSiteGinerProton OnSiteSiemensUnitsModel NumberHyLYZER -1 HyLYZER -2H2H2H6 FuelGen12, Series MerrimackSILYZER 200 basicElectrolysis typePEM (Proton exchange membrane )

10 PEM (Proton exchange membrane )PEM (Proton exchange membrane )PEM (Proton exchange membrane )PEM (Proton exchange membrane )PEM (Proton exchange membrane )PEM (Proton exchange membrane )PEM (Proton exchange membrane )PEM (Proton exchange membrane )Rated stack time:millisecond scale< 10 secSecHydrogen purity (dep. on operating point) Prodution Net Prodution Rate (scfh)38767615222822811621528,550scfh Net Prodution Rate (kg/day) per kg/day per kg/dayTurndown Ratio0 to 100%0 to 100% net product delivery (Automatic)0 to 100% net product delivery (Automatic)0 to 100% net product delivery (Automatic)10:110-100%%Output pressureUp to to bar up to 12 barUp to 35barFeed WaterPotable main water supplyDeionized waterFresh water / Nm H2 Inlet water to to to 41 to 10bargRelative Humidity0 to 90%0 to 90%0 to 90%0 to 90%%Power Supply380 to 480 VAC, 3 phase, 50 or 60 Hz380 to 480 VAC, 3 phase, 50 or 60 Hz380 to 480 VAC, 3 phase, 50 or 60 Hz420-480 VAC, 3 phase, 60 Hz, 112 FLA400 VAC 50 HzCooling strategyAir CooledAir CooledLiquid cooled kWLiquid cooled kWLiquid cooled kWAir or LiquidAir CooledOperating Temperature5 to 405 to 405 to 605 to 605 to 60-23 to 465 to 35 CHydrogen quality :Optional DeOxo dryerHydrogen production under nominal load:Life cycle design.