7 TEA Liquid Alkaline Workshop
7 TEA Liquid Alkaline Workshop
Techno-Economic Review
Strategic Analysis Inc.
Presentation to:
US DOE “Experts Meeting on Advanced Liquid Alkaline Water Electrolysis”
Brian D. James
Jennie Huya-Kouadio
Yaset Acevedo
Kevin McNamara
• LA = Liquid Alkaline
• PEM = Proton Exchange Membrane
• AEM = Anion Exchange Membrane
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TEA Methodology
• Techno-Economic Analysis (TEA) is a tool to evaluate an entire system; evaluating the interactions between
technical performance and cost.
PEM
Electrolysis
EXAMPLE
EXAMPLE EXAMPLE
Traditional/Old-Style LA had a 2-3mm gap between the electrodes and the diaphragm [12].
Modern Zero-Gap Designs press electrodes against the diaphragm.
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Elastic Elements (for Zero Gap Design) to Press Electrode into Diaphragm
Anode
Cathode Shell (5)
Shell (2)
DeNora-Style electrodes (LA & Chlor-Alkali) use an Elastic Element to maintain a constant gap between electrodes.
Traditional designs use a metal box/pan/flange to collect bubbles and route them away from the electrodes.
Membrane (8)
Gas Diffusion Electrode (6)
Porous Material (9) (Ti Foam or other)
Source: [16] (2016 DeNora patent)
Source: [16] (2016 DeNora patent)
A Frame Gasket (with contours) can be used to seal the porous diaphragm.
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SA Baseline Alkaline Cell Design
(SA-representation of traditional LA electrolysis cell)
• Cross-sectional view of single Alkaline electrolysis cell
• Generic cell design: does not exactly match any one company (but is representative of key features)
Centerline
Water and O2 Evolution
Ni wire elastic element: 3.5mm compressed
O2 Gasket Seal: 1mm thick Ni BPP: 0.762mm thickness thickness, 7mm uncompressed thickness,
die cut PEN sheets 0.15mm wire diameter
Bipolar Plate Fine Ni mesh anode substrate: 50 micron
O2 Cell Frame: 1.55mm thick
injection molded PEEK Gasket Seal thickness, 18 micron wire diameter, 350
Cell Frame
Elastic Element micron opening width
O2 Gasket Seal: 1.25mm thick NiMo catalyst: 5 mg/cm2
die cut PEN sheets Gasket Seal Anode
Diaphragm OH– Transport Zirfon (ZrO2/polysulfone) diaphragm: 500
H2 Gasket Seal: 1.25mm thick micron thickness
die cut PEN sheets Gasket Seal Cathode
Cell Frame Fine Ni mesh cathode substrate: 50 micron
H2 Cell Frame: 1.55mm thick Elastic Element thickness, 18 micron wire diameter, 350
injection molded PEEK Gasket Seal micron opening width
H2 Gasket Seal: 1mm thick NiFe(OH)2 catalyst: 5 mg/cm2
die cut PEN sheets
H2 Evolution
SA design used for Baseline Cost Analysis.
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NREL and Hydrogenics (~2017) Alkaline Design
(Both are simplified, PEM-like construction)
Centerline
Ni-coated SS BPP: 0.76mm thick SS (0.2mm etched flow
fields depth) with 25nm PVD Ni coating on both sides
O2 Gasket Seal: 50µm thick
die cut PET sheets
H2 flow channels: 0.2mm
Bipolar Plate O2 PTL anode: 1mm thick sintered porous Ni
O2 Cell Frame: 1.0125mm Gasket Seal (50% porosity)
thick injection molded PEEK Anode O2 PTL
Cell Frame CCM: 250µm thick Zirfon (ZrO2/polysulfone)
Subgasket: 125µm thick PET diaphragm membrane with decal-transfer
Subgasket Diaphragm
sheet abutting the diaphragm - anode (NiMo catalyst: 5 mg/cm2)
- cathode (NiFe(OH)2 catalyst: 5 mg/cm2)
Cell Frame
Cathode H2 PTL
Gasket Seal H2 PTL cathode: 1 mm thick sintered porous
H2 Cell Frame: 1.0125mm Bipolar Plate Ni (50% porosity)
thick die cut HDPE sheets
O2 flow channel depth: 0.2mm
(modeled as 0.2mm depth but likely to be deeper)
H2 Gasket Seal: 50µm thick die cut PET sheets
(alternatively, could insertion mold gaskets on Distinguishing Features:
both sides of BPP at high volume) • No elastic elements • Ni Foam PTL • CCM
• Ni-coated SS BPP • Simplified gaskets • Improved CD (1.2A/cm2, 1.8V)
10 STRATEGIC ANALYSIS, INC.
SA PEM Cell Configuration
• Cross-sectional view of single PEM electrolysis cell
• Generic cell design: does not exactly match any one company (but is representative of key features)
BPP: 0.76mm thick Ti (0.2mm etched flow
Centerline
fields depth) with 25nm PVD Au coating on
H2 side and 25nm PVD Pt coating on O2 side Water and O2 Evolution
O2 Gasket Seal: 50µm thick
die cut PET sheets H2 flow channels: 0.2mm
Bipolar Plate O2 PTL: Sintered porous Ti 1mm thick
Gasket Seal (50% porosity) with 100nm PVD Pt coating
O2 Cell Frame Anode O2 PTL
O2 Cell Frame: 925µm thick CCM: 200µm thick ePTFE-supported PFSA
injection molded HDPE Subgasket membrane with slot die coated catalyst
H+ Transport O2 side: 2mg Ir/cm2 of IrO2 on TiO2
MEA
Subgasket H2 side: 1mg Pt/cm2 at 30% Pt/C + 0.1mg
Subgasket: 100µm thick PET Pt/cm2 for GRC catalyst
sheets encasing membrane H2 Cell Frame Cathode H2 PTL (GDL)
using 3M roll-to-roll process Gasket Seal
H2 GDL: 150µm thick (105µm carbon fiber
Bipolar Plate
substrate with 45µm thick MPL)
O2 flow channel depth: 0.2mm
H2 Cell Frame: 75µm thick (modeled as 0.2mm depth but likely to be deeper)
die cut HDPE sheet H2 Evolution
H2 Gasket Seal: 50µm thick die cut PET sheets
(alternatively, could insertion mold gaskets on
both sides of BPP at high volume)
Illustrates:
• Zero-Gap cell
• Advanced catalyst (RuO2 cathode)
• Applied via thermal decomposition
• Fine Ni mesh electrode substrate
• “Mattress” Elastic Element (on only one side)
• Current Collector
• Cell Frame
• Gaskets against membrane
2014 E4Tech
2000 Nouryon
• These are Prices, not Costs
System Price ($/kW)
Learning Curve
• Trend-line is downward
1500 Public System Price Data
• Lowest priced ~2020 systems
tend to be Chinese
1000
• Full details & assumptions are
not known. (That’s why we are
500 doing a full DFMA-style
analysis)
0
2012 2014 2016 2018 2020 2022 2024 2026 2028 2030 2032
Year
Future Targets:
Stack $<115/kW
BOP minimize ~$500 to
Other minimize 700/kW
Total ~$600-$800/kW
Anode Catalyst
Cathode BPP Membrane
BPP
Anode
Electrodes & BPP ~56% PEM Bipolar Plate cost ~50% of stack cost.
(broadly consistent with Note: Anode/OER catalyst cost is modest
Nouryon projection of 67%) but the analysis pre-dates recent 10x spike in Iridium price
STRATEGIC ANALYSIS, INC. 23
LA Electrolyzer Stack DFMA
Preliminary Results: DFMA Analysis in Progress
Baseline: 5MW Stack (500 MW/year) Future/Advanced: 5MW Stack (500 MW/year)
Trends:
Both Stacks: 1m2 active area • Large cells and large stack powers are cost-favored
Baseline: 0.4 A/cm2 at 1.8 V/cell
Future: 1.0 A/cm2 at 1.8 V/cell • Simplified cell design reduces cost
• Higher power density reduces cost
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LA Electrolyzer Balance of Plant (BOP) Analysis
Preliminary Results: Cost Analysis in Progress
2014 E4tech BOP Cost Breakdown [32] Preliminary SA BOP Cost Breakdown: 25MW BOP Module
Preliminary observations:
• Electrical subsystem (rectification) is a major BOP cost contributor
• Economies of scale observed: what is largest practical BOP sizing?
• Use of BOP modularity will reduce cost but it is hard to reliably quantify
• Economies of manufacturing rate are less-beneficial when BOP-module size is large
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Cost Reduction Strategies/Thoughts (1)
2014 E4tech Recommendations/Assessment [32] SA Thoughts
Zero-Gap Configuration Improves performance
Scale-Up Cell Size Lower waste
Scale-Up Stack Size Looking at 5MW (or greater) stacks
Scale-Up BOP
Benefits to 500kW – 1MW, then flatter curve Benefits to ~25MW (under review)
Components
Examine out to 10GW/year.
Scale-Up
Compare many small stacks or systems
Manufacturing Rate
vs. fewer large stacks (Enapter approach)
Already high efficiency. Focus on reducing cost of high-
System Efficiency
efficiency systems
Already high lifetime (>60kh). Focus on reducing cost of
Lifetime
high-lifetime, high-efficiency, low-cost systems
Need dynamic operation to provide grid services and Can be a key factor in market capture
Dynamic Operation
capture that revenue stream (vs PEM) and competitive LCOH
To improve effective electrode area. Options include:
Bubble Reduction
centrifugal, magnetic fields, ultrasound, microwave
STRATEGIC ANALYSIS, INC. 26
Cost Reduction Strategies/Thoughts (2)
2014 E4tech Recommendations/Assessment [32] SA Thoughts
Stack/System Anticipate incremental improvement in stack and
Improvements system engineering and manufacturing
Demo of multi-MW stacks and systems with reduced 3MW+ stacks already demonstrated.
Multi-MW Systems
footprints and easier commissioning Is 10MW stack practical?
To achieve increased current densities, controlled
Advanced Catalysts morphologies, physiochemical properties, and
stability in alkaline environments
Membrane Lower crossover rates, increased life Can H2 purity be increased?
(Further) manufacturing cost
Factory Builds reduction via streamlined factory
builds
(Further) manufacturing & installation
cost reduction via increased
Modularity
modularity and commonization of
parts/subsystems
Does poor AL turn-down limit
Turn-Down
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Cost Reduction Strategies/Thoughts (3)