Green Hydrogen production has been allocated an important role as part of energy transition strategy to reduce our CO2 footprint. Electrolyzer stacks have been developed and commercialized to convert pure water into hydrogen and oxygen. Large multinational companies have now entered the “field of hydrogen” with the intent and capacity to industrialise and automate stack manufacturing, thus bringing down costs through the economy of scale. Our core strength is focused around the bipolar plate design, material choice and protective coating types, for application in an optimized water-electrolyzer stack for PEM or AEM applications. Schaeffler [1] is driving additional technological development projects with strong financial backing of European (CHP) and German funding (H2Giga). PEM water electrolysis is regarded as powerful technology, bringing advantages of limited installation footprint, broad range of operating conditions, especially in terms of dynamic load range and featuring high efficiency between 75-90% (based on HHV) [2]. In this work we estimate how much the stack technology can be improved further by leveraging formed BPP metal structures and optimizing the structural elements and component design using CFD. Especially when scaling stack hardware to larger capacity, there is much emphasis on enhanced thermal management to avoid hot-spots and mitigate non-uniform degradation mechanisms and premature stack failure. Simulation results will show how flow designs could be adapted maintain uniform conditions when scaling up the active area or adding more cells to the stack. Simulation results will be compared with operational stack data for small screener stacks up to large MW-level cell platforms. We show how we can optimize flowfield flow structures, staying within the manufacturing limits of the material at hand, being titanium or stainless steel. Both processes rely on simulation software [3] to answer many critical questions, including how to identify the most influential parameters for hydrogen production, for example: current density regime, pitch between plate, the temperature of the feedwater, or the outflow water. Also, if there is a separate cooling loop available, we demonstrate what the ultimate thermal control solution could look like to save cost and gain operational lifetime. The hydrogen economy benefits most from accelerating our iterative pathway towards an optimum BiPolar Plate design comprising a structured flowfield for uniform flow distribution and a material composition bringing overall cost/performance benefits. Once the industry has agreed upon a standardized electrolyzer stack geometry, our combined economy of scale will have a greater positive impact on the business case.
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