(Invited) Electrolyser Manufacturing Scale-up Versus Design Development for Meeting Green H2 Targets

Abstract

Cummins-Hydrogenics pioneered our MW-scale PEM electrolysis cell stack architecture in 2012 and has built and operated multiple sites since, including the 20 MW Bécancour facility for Air Liquide from 2020. Lessons learned from these projects provide a springboard for large-scale manufacturing and deployment of PEM electrolysers worldwide and Cummins has announced GW-scale manufacturing deployment in Europe, N America and Asia. This is required to meet the growing global demand for PEM electrolysers, which derives from the targets and subsidies for green hydrogen production announced by many governments.Concurrent to this manufacturing scale-up, significant work on cost reduction and technology advancement is ongoing resulting in anticipated cost decreases from catalyst loading (Ir<150g/MW), efficiency improvements (<46 kWh/kg) and higher current density, all of which need to be achieved for commercial viability. Driving down the Ir-loading of PEM electrolysers while increasing current densities will remain the primary driver of CapEx reductions in the short to medium term but the deployment of large-scale manufacturing also allows for significant economies of scale. Recycling and regeneration of used components will also become a larger issue and new processes need to be implemented for each stack component.Moving from a project-based design methodology to design for volume manufacturing, all while maintaining the fast pace of technology development, makes for significant challenges and can lead to processing waste and inefficiencies. Rigorous testing and validation protocols are needed across the industry in order to successfully scale-up while implementing technology improvements necessary to meet TCO targets. This talk will focus on the juxtaposition of these challenges and ways to mitigate future risks.