Manufacturing Challenges and Opportunities for PEM Electrolysis

Hydrogen generation via electrolysis has gained much attention internationally as not only a sustainable source of fuel for the transportation, but as a carrier of energy to capture stranded renewable due to the carbon-free chemical cycle and response characteristics of the technology. The barrier to entry preventing this technology from being widely adopted is the overall cost associated with both the upfront capital expense as well as the operating cost incurred over the product life. The majority of this cost is driven by 1) low electrical efficiencies due to the high ohmic resistance of thicker membranes required by electrolysis systems to electrochemically compress generated hydrogen for storage and the overpotential associated with the water splitting oxygen evolution reaction (OER) catalysts typically used, 2) high cost of system and cell stack materials, which need to be durable for up to 100,000hrs at a potential of 2V in both reducing and oxidizing environments, and 3) the lack of a robust supply chain for high volume manufacturing to further drive down cost through economies of scale. With 95% of hydrogen currently being produced through the reformation of cheap natural gas, significant cost reductions are necessary for electrolysis to become a viable alternative to the incumbent. Commercial proton exchange membrane (PEM)-based electrolysis has reached scales of several hundred kg/day, providing a relevant pathway for industrial scale hydrogen generation with tremendous opportunity for continuing cost reduction by leveraging system and manufacturing scaling laws by leveraging advancements in PEM fuel cell materials, manufacturing, and analysis tools. Order of magnitude improvements in some of the highest cost elements are easily achievable and with more research funding being directed towards hydrogen production, the realization of these reductions are occurring at a faster rate. While many improvements in stack design and materials of construction have been identified and implemented, there are still numerous opportunities to explore that would move electrolysis towards a viable, cost-effective alternative to natural gas reformation. This talk will describe some of the areas of success, where research is still needed, and ultimately how each of these improvements translate into cost and the path to reformation parity.