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Manufacturing Competitiveness Analysis For PEM and Alkaline Water Electrolysis Systems

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Manufacturing Competitiveness Analysis for

PEM and Alkaline Water Electrolysis Systems

Mark Ruth (Presenter), Ahmad Mayyas, and


Maggie Mann
National Renewable Energy Laboratory
Fuel Cell Seminar and Energy Expo
11/08/2017
CEMAC – Clean Energy Manufacturing Analysis Center 1
Agenda

I. Introduction
II. PEM Electrolyzer - Functional Specs & System Design
III. Alkaline - Functional Specs & System Design
IV. Cost Analysis for PEM and Alkaline Electrolyzer

V. Concluding Remarks

CEMAC – Clean Energy Manufacturing Analysis Center 2


I Introduction

CEMAC – Clean Energy Manufacturing Analysis Center 3


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?
Source: UkH2Mobility
CEMAC – Clean Energy Manufacturing Analysis Center 4
Comparison between PEM and
Alkaline Electrolyzers
Characteristics Alkaline PEM Unit Notes

Current Density 0.2 - 0.7 1.0 - 2.2 A/cm2

Operating Temperature 60 – 80 50 – 84 °C
Electricity Consumption 50 – 73 47 – 73 kWh/kg-H2 Electrolysis system only. Excluding
storage, compression and
(Median) (53) (52) dispensing

Min. Load 20 - 40% 3 – 10%


Startup Time from Cold to Min. Load 20 min - 60+ 5 – 15 minutes
System Efficiency (LHV) 45-67% 45 – 71%
(Median) (63%) (63%)
System Lifetime 20-30 10-30 Year
(Median) (26) (22)
System Price $760 – $1,100 $1,200-$1,940 Including power supply, system
control and gas drying. Excluding
($930) ($1,570) grid connection, external
compression, external purification
and H2 storage

Sources of data: Bertuccioli et al., 2014, NREL 2017


CEMAC – Clean Energy Manufacturing Analysis Center 5
II PEM Electrolyzer - Functional Specs & System Design

CEMAC – Clean Energy Manufacturing Analysis Center 6


PEM Electrolyzer System Design
High Voltage Supply

Back Pressure
Regulator
Transformer Rectifier
City
Water H2
Combustible Demister
Gas Detector
Water
Cleaner H2 Low
Pressure
H2 O Storage
Water/H2
Separator
O2 Electrolyzer
Stack Dryer
Demister
Heat Controllable
Pump Exchanger Valve
Oxygen/ GDL = Porous Transport Layer
DI
Water Water
Phase
Separator

Hot Water

* Stack components picture from greencarcongress.com


CEMAC – Clean Energy Manufacturing Analysis Center 7
Derived Functional Specifications
Stack Power 10 20 50 100 200 500 1,000 2,000 5,000 10,000 kW
single cell amps 1224 A
current density 1.80 A/cm2
reference voltage 1.619 V
power density 2.913 W/cm2
2
Pt-Ir loading- Anode 7.0 g/m
2
PGM loading Cathode 4.0 g/m
single cell power 1981.0 W
Cells per system 5 10 25 50 101 252 505 1010 2524 5048 cells
stacks per system 1 1 1 1 1 1 2 4 10 20 stacks
cells per stack 5 10 25 50 101 252 252 252 252 252 cells

Part Assumptions Notes


Membrane Nafion 117 (Purchased) PFSA (PEEK, PBI)
Pt Pt-price= 1500/tr.oz DOE Current value
CCM Spray Coating Platinum loadings:
Anode= 7g/m2 (Pt)
Cathode= 4g/m2 (Pt-Ir)
Porous Transport Sintered porous titanium Porosity=30%
Layer Ti-price= $4.5/kg
Seal/Frame Screen printed PPS-40GF or Seal: 0.635 cm from each side for
PEEK seal MEA bonding
Plates Stainless steel 316L Coated (plasma Nitriding)
CEMAC – Clean Energy Manufacturing Analysis Center 8
III Alkaline Electrolyzer - Functional Specs & System Design

CEMAC – Clean Energy Manufacturing Analysis Center 9


Alkaline Electrolyzer System
High Voltage Supply

Back Pressure
Regulator
Transformer Rectifier
City
Water H2
Combustible Demister
Gas Detector
Water
Cleaner H2 + H2O
+ KOH H2 O
Flow Direction +
Flow KOH Phase
O2 + H2O + KOH Direction
Separator
O2
Dryer
Demister

Heat Controllable H2 Low


Phase Exchanger Valve Pressure
KOH + Pump
Separator H O Storage
2

H2O + KOH Alkaline


Electrolyzer
Electrolyte Flow
Direction Stack

H2O + KOH
Flow Direction
CEMAC – Clean Energy Manufacturing Analysis Center 10
Alkaline Electrolyzer - Functional Specs
System rated power 10 20 50 100 200 500 1,000 2,000 5,000 10,000 kW
Electrolyte H2O+ 30% KOH H2O+ 30% KOH
Single cell amps 150 150 150 150 150 150 300 300 300 300 A
Current density 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 A/cm2
Reference voltage 1.68 1.68 1.68 1.68 1.68 1.68 1.68 1.68 1.68 1.68 V
Area Doubled
Power density 0.336 0.336 0.336 0.336 0.336 0.336 0.336 0.336 0.336 0.336 W/cm2
Single cell power 252.0 252.0 252.0 252.0 252.0 252.0 504.0 504.0 504.0 504.0 W
Cells per system 40 80 199 397 794 1,985 1,985 3,969 9,921 19,842 cells
Stacks per system 1 1 2 2 4 10 10 20 50 100 stacks
cells per stack 40 80 100 199 199 199 199 199 199 199 cells

Part Materials Notes


Membrane m-PBI Cast membrane using doctor-
blade machine
Electrodes Raney- PVD + Leaching to get the
nickel required porosity
Porous Pure Nickel Corrosion resistance in alkaline
Transport Sheets solution
Layer
Frame PPS-40GF or Injection molding
PEEK
Plates Nickel Surface treatment of high
plates purity sheets
PVD: physical vapor deposition
CEMAC – Clean Energy Manufacturing Analysis Center 11
IV Cost Analysis for PEM and Alkaline Electrolyzer

CEMAC – Clean Energy Manufacturing Analysis Center 12


PEM - Bipolar Plate
Case Hardening (Nitriding)
Coil - Stainless
Blanking Stamping
Steel 316L
N2 Gas + High Voltage
and Temperature
Cleaning
Plasma Nitriding Cleansing
(Chemical Bath)
Plasma Nitriding Furnace

Final Plate

CEMAC – Clean Energy Manufacturing Analysis Center 13


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 14
PEM – Stack Assembly

65 kg H2/day 385 kg H2/day


CEMAC – Clean Energy Manufacturing Analysis Center 15
Alkaline - Raney Nickel Electrodes
Process Flow Diagram

Ni-Sheets PVD Leaching


Degreasing Ar Sputtering 1% NaOH
Thickness = ½mm

To remove NiO from 2 hr


the surface @RT

Electrode Leaching
Leaching
Assembly 10% NaOH 10% NaOH
Membrane
4 hr 20 hr
@100°C @RT

Leaching can be made in one step with longer time and


higher concentration of NaOH (~30%)

Image from Chade


et al., 2013
Based on Kjartansdo´ttir et al., 2013
CEMAC – Clean Energy Manufacturing Analysis Center 16
Alkaline - Raney Nickel Electrodes
Preliminary

Preliminary

CEMAC – Clean Energy Manufacturing Analysis Center 17


Manufacturing Cost of Electrolyzer Stacks

• Alkaline electrolyzer stacks have


larger cost in $/kg-H2

• Cost curve for a 200kW system

A 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 18


Manufacturing Cost of Electrolyzer Stacks

• Alkaline electrolyzer stacks have


larger cost in $/kg-H2 basis

• Cost curve for a 1MW system

A 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


V Concluding Remarks

CEMAC – Clean Energy Manufacturing Analysis Center 20


Conclusions
• Alkaline water electrolyzers have lower current and
power densities, but have lower initial cost (per kW
basis)
• PEM electrolyzers may have lower stack cost in ($
per Nm3/hr)
• Good similarities in manufacturing processes for
PEM and alkaline electrolysis (e.g., membrane
casting, plates stamping & coating, end plates,
stack assembly, etc.)

CEMAC – Clean Energy Manufacturing Analysis Center 21


Questions?

Mark Ruth
Mark.Ruth@nrel.gov

Ahmad Mayyas
Ahmad.Mayyas@nrel.gov

CEMAC – Clean Energy Manufacturing Analysis Center 22


THANK YOU!
NREL/PR-6A20-70380

This work was authored by the National Renewable Energy Laboratory, operated by Alliance for Sustainable
Energy, LLC, for the U.S. Department of Energy (DOE) under Contract No. DE-AC36-08GO28308. Funding
provided by the U.S. 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 U.S. Government. The U.S. Government retains and the publisher, by accepting the article for publication,
acknowledges that the U.S. 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 U.S. Government purposes.

CEMAC – Clean Energy Manufacturing Analysis Center 23


Backup Slides

CEMAC – Clean Energy Manufacturing Analysis Center 24


FCEV 2015-2024

CEMAC – Clean Energy Manufacturing Analysis Center 25


International Manufacturer of Onsite Hydrogen
Production System

This map can be accessed from https://maphub.net/mayyas111/Onsite-H2-Production-Equipment


CEMAC – Clean Energy Manufacturing Analysis Center 26
PEM Electrolysis

CEMAC – Clean Energy Manufacturing Analysis Center 27


PEM - Functional Specifications
Manufacturer Hydrogenics Hydrogenics Proton OnSite Proton OnSite Proton OnSite Proton OnSite Giner Proton OnSite Siemens Units
Model Number HyLYZER™-1 HyLYZER™-2 H2 H2 H6 FuelGen12, Series Merrimack SILYZER 200 basic
PEM (Proton PEM (Proton PEM (Proton PEM (Proton PEM (Proton PEM (Proton PEM (Proton PEM (Proton
PEM (Proton
Exchange Exchange Exchange Exchange Exchange Exchange Exchange Exchange
Exchange Membrane)
Electrolysis type Membrane) Membrane) Membrane) Membrane) Membrane) Membrane) Membrane) Membrane)

Rated stack Consumption 7.20 14.40 14.00 28.00 40.00 45.00 160.00 250.00 1250.00 kW
Startup time: millisecond scale < 10 sec Sec
Hydrogen purity (dep. on
operating point): 99.9995% 99.9995% 99.9995% 99.9995% 99.3-99.8% 99.5% – 99.9%
System Effciency 6.70 6.70 7.30 7.00 6.80 7.50 6.25 5.56 kWh/Nm3
Net Prodution Rate 1 2 2 4 6 6 30.59 40 225 Nm3/h
Net Prodution Rate
(scfh) 38 76 76 152 228 228 1162 152 8,550 scfh
Net Prodution Rate
(kg/day) 2.16 4.32 4.31 8.63 12.94 12.95 66.00 86.30 485.46 kg/day
kW per kg/day ratio 3.34 3.34 3.25 3.24 3.09 3.48 2.42 2.90 2.57 kW per kg/day
0 to 100% net 0 to 100% net 0 to 100% net
product delivery product delivery product delivery
System Turndown Ratio 0 to 100% (Automatic) (Automatic) (Automatic) 10:1 10-100% %
Output pressure Up to 7.9 Up to 7.9 15 0-40 bar up to 12 bar Up to 35 bar
Potable main
Feed Water water supply Deionized water
Fresh water demand: 1 1 1.83 3.66 5.5 54 3.4 ltr/hr 1.5 ltr / Nm³ H2
Inlet water pressure 0.7-6.9 0.7-6.9 1.5 to 4 1.5 to 4 1.5 to 4 1 to 10 barg
Relative Humidity 0 to 90% 0 to 90% 0 to 90% 0 to 90% %
208/120,3 phase,4 wire+gnd,50/60
Hz 200-260,1 phase,2 wire+gnd, 380 to 480 VAC, 3 380 to 480 VAC, 3 380 to 480 VAC, 3 420-480 VAC, 3
50/60 Hz Direct connection to DC phase, 50 or 60 Hz phase, 50 or 60 Hz phase, 50 or 60 Hz phase, 60 Hz, 112
Power Supply possible upon request. FLA 400VAC 50Hz
Liquid cooled 16.1 Liquid cooled 23.7
Cooling strategy Air Cooled Air Cooled Liquid cooled 8.1 kW kW kW Air or Liquid Air Cooled
Operating Temperature 5 to 40 5 to 40 5 to 60 5 to 60 5 to 60 -23 to 46 5 to 35 °C
Hydrogen quality 5.0: Optional DeOxo dryer
Hydrogen production
under nominal load:
Life cycle design: > 80,000 h
CE Mark with
CE Approved PED and ASME Yes Yes
Circular cells
Other Specs Other Specs with 300 cm2
1.30 X 1.00 X 180 cm x 81 cm x 180 cm x 81 cm x 180 cm x 81 cm x
Dimensions 0.75 X 0.66 X 1.17 1.25 191 cm 191 cm 191 cm 2.18 X0.84 X1.91 0.85 X 1.05 X 1.65 6.3 X 3.10 X 3.00 mXmXm
Weight 250 275 682 858 908 900 260 17000 kg

CEMAC – Clean Energy Manufacturing Analysis Center 28


CCM Slot-Die Coating Process
Cathode

Anode

CEMAC – Clean Energy Manufacturing Analysis Center 29


CCM Slot-Die Coating Process
Final CCM

CEMAC – Clean Energy Manufacturing Analysis Center 30


Powder Metallurgy for GDL

GDL or Porous Transport Layer Image source: http://erean.eu/wordpress/powder-metallurgy-and-permanent-magnets/


CEMAC – Clean Energy Manufacturing Analysis Center 31
Porous Transport Layer = GDL

Grigoriev et al., 2007


CEMAC – Clean Energy Manufacturing Analysis Center 32
Proposed Cell/Plates/Seal Structure
Cathode Plate
Seals

Frame MEA Cell

Anode Plate

Cathode Layer
Porous Ti GDL Nafion Membrane
Anode Layer

CEMAC – Clean Energy Manufacturing Analysis Center 33


Balance of Plant Cost (Parts Only)
System Size kW 10 20 50 100 200 500 1,000 2,000 5,000 10,000
Baseline Cost ($)
Sizing
System Subsystem 10 kW 20 kW 50 kW 100 kW 200 kW 500 kW 1 MW 2 MW 5 MW 10 MW
Exponent (if
Power Supplies Power Supply Quote (AEG) $3,000 $5,080 $22,733 $27,331 $44,000 $132,000 $198,000 $335,500 $734,250 $1,405,250
DC Voltage Transducer Quote $225 $225 $225 $225 $225 $225 $225 $225 $225 $225
DC Current Transducer Quote $340 $340 $340 $340 $340 $340 $340 $340 $340 $340

Total $3,225 $5,305 $22,958 $27,556 $44,225 $132,225 $198,225 $335,725 $734,475 $1,405,475

Deionized Water
Quote
Circulation Oxygen Separator Tank $10,000 $10,000 $10,000 $10,000 $20,000 $20,000 $40,000 $80,000 $160,000 $320,000
Circulation Pump Quote $409 $647 $1,538 $3,349 $7,053 $10,000 $10,962 $20,000 $40,000 $80,000
Quote
Polishing Pump $1,619 $2,071 $2,071 $2,289 $2,289 $2,500 $5,000 $10,000 $20,000 $40,000
Piping 0.30 $3,807 $4,687 $6,170 $7,597 $10,000 $12,311 $15,157 $18,661 $24,565 $30,243
Valves, Instrumentation 0.30 $2,855 $3,516 $4,628 $5,697 $7,500 $9,234 $11,368 $13,995 $18,423 $22,682
Pressure, temperature, conductivity, flowmeter
Class I, Div 2, Group B rating drives up prices
Controls 0.60 $2,000 $2,000 $2,000 $2,000 $2,000 $3,031 $4,595 $6,964 $12,068 $18,292
Total $20,691 $22,921 $26,407 $30,932 $48,842 $57,076 $87,082 $149,621 $275,056 $511,217

Hydrogen Processing Dryer Bed $6,366 $6,366 $13,860 $13,860 $13,860 $25,000 $36,589 $73,178 $146,356 $292,712
Hydrogen Separator 0.70 $1,051 $1,707 $3,241 $5,266 $10,000 $16,245 $26,390 $42,871 $81,418 $132,264
Tubing 0.30 $1,904 $2,344 $3,085 $3,798 $5,000 $6,156 $7,579 $9,330 $12,282 $15,121
Valves, Instrumentation 0.30 $1,904 $2,344 $3,085 $3,798 $5,000 $6,156 $7,579 $9,330 $12,282 $15,121
Pressure, temperature, conductivity, flowmeter
Class I, Div 2, Group B rating drives up prices
Controls 0.60 $362 $549 $952 $1,443 $2,500 $3,789 $5,743 $8,706 $15,085 $22,865

Total $11,586 $13,309 $24,223 $28,165 $36,360 $57,346 $83,880 $143,415 $267,424 $478,084

Cooling Plate heat exchanger $9,000 $9,000 $9,000 $9,000 $9,000 $9,000 $10,525 $11,675 $14,742 $14,742
Cooling pump Quote (n=0.67) $970 $1,169 $1,169 $1,500 $1,500 $2,387 $3,797 $6,042 $11,163 $17,761
Valves, instrumentation 0.60 $2,000 $2,000 $2,000 $2,000 $2,000 $3,031 $4,595 $6,964 $12,068 $18,292
Piping 0.60 $1,000 $1,000 $1,000 $1,000 $1,000 $1,516 $2,297 $3,482 $6,034 $9,146
Dry cooler 0.45 $4,000 $4,000 $4,000 $4,000 $4,000 $5,464 $7,464 $10,196 $15,400 $21,037
Total $16,970 $17,169 $17,169 $17,500 $17,500 $21,398 $28,679 $38,360 $59,408 $80,979

Miscellanous Valve air supply – nitrogen or compressed air n/a $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000
Ventiliation and safety requirements n/a
Combustible gas detectors n/a $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000
n/a
Exhaust ventiliation $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000 $2,000

Total $6,000 $6,000 $6,000 $6,000 $6,000 $6,000 $6,000 $6,000 $6,000 $6,000

Grand Total ($) $58,472 $64,704 $96,758 $110,153 $152,927 $274,045 $403,865 $673,120 $1,342,363 $2,481,754
CEMAC – Clean EnergyCost
Manufacturing
($/kW) Analysis Center $5,847 $3,235 $1,935 $1,102 $765 $548 $404 $337 $268 $248 34
Power Supply Cost

CEMAC – Clean Energy Manufacturing Analysis Center 35


Balance of Plant Cost (Parts Only)

CEMAC – Clean Energy Manufacturing Analysis Center 36


Alkaline Electrolysis

CEMAC – Clean Energy Manufacturing Analysis Center 37


Alkaline Electrolyzer Stack

Cells are assembled electrically in series, hydraulically in parallel.


Picture of Hydrogenics Alkaline Electrolyzer
CEMAC – Clean Energy Manufacturing Analysis Center 38
Commercial Alkaline Electrolyzers
Pure Energy
Hydrogenics Hydrogenics Hydrogenics Units
Manufacturer Center
Model Number HySTAT 15 HySTAT 30 HySTAT 60
Electrolysis type Alkaline Alkaline Alkaline Alkaline
Rated stack Consumption 22.30 145.00 270.00 515.00 kW
Electrolyte H2O+ 30% KOH H2O+ 30% KOH H2O+ 30% KOH
Hydrogen purity (dep. on
operating point): 99.3-99.8 99.9 99.9 99.9 %
3
System Effciency 5.58 4.90 5.20 4.90 kWh/Nm
3
Net Prodution Rate 4 6 to 15 12 to 30 24 to 60 Nm /h
Net Prodution Rate
(scfh) 227 to 570 456 to 1140 912 to 2280 scfh
Net Prodution Rate
(kg/day) 13 to 32 26 to 65 52 to 130 kg/day
System kWh per kg ratio 62.08 54.52 57.86 54.52 kWh//kg
Turndown Ratio 10-100% %
Output pressure up to 12 bar 10 10 10 bar
Feed Water Deionized water
Fresh water demand: ltr / Nm³ H2
Inlet water pressure barg
Relative Humidity <95 <96 <96 %
Power Supply 400 VAC; 50 Hz 3*400 VAC 50 Hz
Cooling strategy Air or liquid Water cooled Water cooled Water cooled
Operating Temperature 5-35 °C
Certification CE Approved
Other Specs
Other Specs Dimensions 1.65 6 3.22X1.81X2.53 mXmXm
Weight 260 3800 kg

CEMAC – Clean Energy Manufacturing Analysis Center 39


Electrode Materials
• Decomposition (corrosion) to cost ratio
 Zinc, iron and brass would perform better
than other metals

• From the current density perspective


 Silver, iron and nickel would perform
better than other metals
Symes et al., 2013
CEMAC – Clean Energy Manufacturing Analysis Center 40
Alkaline Electrolyzer Power Density

Current density 0.200 A/cm2


Reference voltage 1.68 V
Power density 0.336 W/cm2

CEMAC – Clean Energy Manufacturing Analysis Center 41


Alkaline Electrolyzer Configuration

CEMAC – Clean Energy Manufacturing Analysis Center 42


Zero Gap Cell Design

Phillips and and Dunnill, 2016


CEMAC – Clean Energy Manufacturing Analysis Center 43
Stack Components

• Catalyst coated substrate (CCS) design eliminates the need for gas diffusion layers
• Bipolar plates (current collectors) with integrated flow fields, provide:
– 1) path for electrolyte (in and out)
– 2) efficient removal of product gases from the cell
– 3) heat management
Phillips and Dunnill, 2016
CEMAC – Clean Energy Manufacturing Analysis Center 44
Electrode Materials
Raney nickel is an alloy of
aluminum and nickel, which
has subsequently had much
of the aluminum removed
through a leaching process
with sodium hydroxide
(NaOH). The remaining alloy
has a very high surface area
and also contains hydrogen
gas (H2) adsorbed on the
nickel surface

Image from:
http://www.masterorganicchemistry.com/
2011/09/30/reagent-friday-raney-nickel/

HER: Hydrogen Evolution Reaction Table from Bodner et al., 2015


CEMAC – Clean Energy Manufacturing Analysis Center 45
Membranes
Membrane Ion Conductivity Thickness Cell Current Manufacturer Ref.
Exchange (mS/cm) Density†
Capacity (mA/cm2)
Tokuyama A201 1.68 ± 40 28 μm 400 @1.8V Tokuyama, Bodner et al.,
0.08 (Japan) (2015)
Ren et al., (2014)
Nafion 117 0.91 90.6 178 μm n/a DuPont (USA) Ren et al., (2014)

m-PBI n/a 100 50-60 μm 400 @2V Danish Power Kraglund et al.,
poly(2,2-(m- Systems (2016)
phenylene)-5,5- (Denmark),
bibenzimidazole) Advent (USA)
Zirfon™ Perl UTP Ionic 500 ± 50 250 @2V Agfa-Gevaert
500 resistance≤0.3 µm (Belgium)
(polyphenylene Ω.cm² at 30†
sulphide/zirconi
um oxide)
xxx

† Assuming 30% KOH

CEMAC – Clean Energy Manufacturing Analysis Center 46


Membrane

* This table is copied from Bodner et al., 2015


CEMAC – Clean Energy Manufacturing Analysis Center 47
PBI-based Membrane - Preliminary
BOM- 1st Generation Monomers
Materials Suppliers Price
Pyridine dicarboxylic acids Sigma-Aldrich Chemical Co. $126 for100mg
(2,4-, 2,5-, 2,6- and 3,5- Matrix Scientific $91 for 25 g
PDA) Alpha Aeser Chemical Co. $212 for 500 g
3,3′,4,4′-Tetraaminobiphenyl Sigma-Aldrich Chemical Co. $250 for 25 g
(TAB) TCI America $126 for 25 g
Tetra-Hedron $380 for 100 g
Polyphosphoric acid (115%) Sigma-Aldrich Chemical Co. $60 for1 kg
(PPA)
Ammonia Hydroxide Sigma-Aldrich Chemical Co. $340 for 6X2.5L
Distilled water Sigma-Aldrich Chemical Co.
Phosphoric Acid (Conc. 85% Duda Energy $40 per gallon
for doping)
Dimethylacetamide (DMAc) Sigma-Aldrich Chemical Co. $542 for 6L
Alpha Aeser Chemical Co. $82.5 for 2.5L

CEMAC – Clean Energy Manufacturing Analysis Center 48


Manufacturing of PBI-based Membrane

Milling & Mixing


(PDA, TAB, PPA)

DMAc
Melting @ 200°C

Casting Process

Image from Xiao et al., 2005


Hydrolysis @ RT & RH=40±5%

Doping in Phosphoric Acid

Drying @ RT

CEMAC – Clean Energy Manufacturing Analysis Center 49


Casting Process
PDA
PPA
TAB
Control Unit
(Temp., Pressure, Viscosity)
Melting
Container

QC Station

Slot-die
Regulator Drying Oven
coater

Substrate
Removal
Winding Roll
Backing
Layer Spool

PDA: Pyridine Dicarboxylic Acids


TAB: Tetra-Amino Biphenyl
PPA: PolyPhosphoric Acid

CEMAC – Clean Energy Manufacturing Analysis Center 50


BPI Membrane Cost Analysis- Preliminary

• Bill-of materials based on


1st generation materials
(Xiao et al., 2003).

• Cost includes capital,


building, operational,
labor, material and scrap
cost components.

CEMAC – Clean Energy Manufacturing Analysis Center 51


Nickel Bipolar Plates

48 kg/day 240 kg/day


CEMAC – Clean Energy Manufacturing Analysis Center 52
Anderson, 2015

CEMAC – Clean Energy Manufacturing Analysis Center 53


PEM and Alkaline Electrolyzer Capital Cost

Bertuccioli et al. 2014


CEMAC – Clean Energy Manufacturing Analysis Center 54
Waterfall Chart – Capital Cost

• Assumptions:
– Economies of scale: cost of producing 100 unit/yr vs. 10 units/yr
– Power electronics : 10% cost reduction
– Improvement in power density: +20% (from 2.91 W/cm2 to 3.50 W/cm2)
– Pt loading: reducing PGM loading from 11 g/m2 to 5 g/m2
– Membrane cost: 20% cost reduction

CEMAC – Clean Energy Manufacturing Analysis Center 55


Effect of Electrolyzer Capital Cost on H2 Cost

CEMAC – Clean Energy Manufacturing Analysis Center 56


Comparative Cost Analysis (Stack Only)

65 kg H2/day 48 kg H2/day

CEMAC – Clean Energy Manufacturing Analysis Center 57


Comparative Cost Analysis (Stack Only)

385 kg H2/day 250 kg H2/day

CEMAC – Clean Energy Manufacturing Analysis Center 58


Alkaline vs. PEM Electrolyzer
• Alkaline electrolyzer stacks have
larger cost in $/kg-H2 basis and in
$/kW basis

CEMAC – Clean Energy Manufacturing Analysis Center 59

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