high efficiency large pem electrolyzers · high efficiency large pem electrolyzers monjid hamdan...

High EfficiencyLarge PEM

Electrolyzers

Monjid HamdanDirector of Engineering

Giner, Inc.89 Rumford Ave, Newton, Ma. 02466

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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

Synergy of Giner, Inc. Technologies

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

GINER, Inc.

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Laboratory Hydrogen

Vehicle ApplicationsElectrolyzer Stacks Electrolyzer Systems

Differential Pressure

Balanced Pressure

Anode Feed

Cathode Feed

Vapor Feed

Static Feed

Regenerative(Combined Fuel-Cell

& Electrolyzer)

Electrochemical H2-Compressors

Oxygen Concentrators

On-Site H2Generators

Life Support

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Giner Electrolyzers

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Membrane Supports

Laser-Drilled

Cast

3D Substrates

Chemically Etched

Membrane Development

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

R&D funded U.S.

Department of Energy

Giner Dimensionally Stable Membranes (DSMTM):

High-strength, High-efficiency membranes

7Nafion is a registered trademark of E.I. du Pont Nemours and Company

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 kWhe/kg-H2 @ 1500 mA/cm²

MEAs utilize low-loaded catalyst loadings (reduced by 90%)

Scaled-up Membrane Performance Demonstrated 5,000+ hrs lifetime of scaled-up DSM

membrane at 80C DSM MEA from 5-cell short stack re-assembled into

a single-cell stack, total testing time = 5,430 hours Efficiency: up to 88% (HHV) @ 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

Membrane Lifetime

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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

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Membrane Durability

Stack Efficiency Vs. Cost of H2 Production Hydrogen production cost dominated by feedstock

Feedstock is largest $ contributor Efficiency is key to cost competitiveness! Larger benefit for MW Scale

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H2 Production Cost Component Breakdown

Feedstock

H2 Forecourt Station

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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 Electrolyzer1st to market with 47 kWh/kgstack @ 1700 mA/cm²Rapid market penetrationProduct sold in 7 CountriesProduct exclusively used inrenewable energy applications Marked

Stack Advancements & Cost Reductions Fluid End Plate

Positive Terminal

Negative Terminal

End Plate

Rep

eatin

g C

ell U

nit

Cell Frame (O2)

Cell SeparatorAnode Support Mat’l

Cathode Support Mat’lCell Frame (H2)

MEA

The repeating cell unit comprises 90% of electrolyzer stack cost

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30 to 90 Nm3/hr

Part Count Required to

Generate 1500 kg-H2/day

Improving Pressure Capabilities of PEM Electrolyzers

Hydrogen at 5,000 psig(350 Bar), Ambient O2Generated

directly in PEM Electrolyzer

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Advantages of High Pressure PEM Electrolysis

Eliminates one or more stages of mechanical compression

Reduces system complexity Lower drying requirements

Low maintenance No moving parts No contaminants

Cross-cutting technology, applicable to Electrochemical Hydrogen Compressors

Permits hydrogen generation at user end-site

DSMTM Enabling Technology

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

High Pressure Electrolyzer Systems

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FCV Home Refueling

Increasing electrolyzer pressure leads to system simplification, but remaining challenges exist:

Validation at National Renewable Energy Laboratory

System Validated at NREL in June 2012 Nominal operating conditions: 1500 -1900 mA/cm²

High stack voltage efficiency: >87% HHV; Energy efficiency;46.6 kWhe/kg-H2

Stack Efficiencies in line with DOE 2012 Targets Development of low-cost high-efficiency components

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

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~87.5% @ 1500 mA/cm²

NREL Report: Milestone 3.7.6 (CPS 52066)

Giner Stack Efficiency

Third Party Validation Giner commercial electrolyzer

stack in-use at Areva Site Operating at multiple sites Customer confirms 2,000

hours at 47 kWhe/kg 1,700 mA/cm²

Electrolyzer Stack Validation

Modular RFC systems with energy storage

from 0.2 to 2MWh

AREVA’s energy storage platform‘GREENERGY BOX’

in Corsica, France Utilizing GES Low-Cost Electrolyzer Stack

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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

Large Scale Electrolysis Led by Market Demand

30-90 Nm3/hr

2-3 Nm3/hr

0.05 Nm3/hr

Next step:>220 Nm3/hr(MW Scale)

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 Commission1

2020 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 emissions1http://ec.europa.eu/energy/energy2020/roadmap/doc/com_2011_8852_en.pdf

Timeline : 1995 2000 2005 2010 2015

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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,…

MW Scale PEM Electrolysis

Single Stack220+ Nm3/hr

MW Electrolyzer

Stack

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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

Summary

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Thank You!Director of Engineering

Monjid [email protected]

+1 781 529 0526

Director of Business DevelopmentHector Maza

[email protected]+1 781 529 0589

www.ginerinc.com

Hall 27, D 76/2

high efficiency large pem electrolyzers · high efficiency large pem electrolyzers monjid hamdan...

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