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Technology

GENERAL INFORMATION

Green hydrogen, produced through the electrolysis of water powered by renewable energies such as solar, wind, geothermal, and hydro, has garnered widespread popularity. This is due to the abundance of renewable energy sources in many countries, the availability of freshwater or desalinated water, and the maturity of renewable technologies. Among the various electrolyser technologies, several have gained prominence in recent years. These include Alkaline Water Electrolysers (AWE), Proton Exchange Membrane Electrolysers (PEM), Solid Oxide Electrolysers (SOEC), and Anion Exchange Membrane (AEM) Electrolysers. While other electrolyser technologies exist, they have yet to reach the pre-commercialisation phase or be manufactured on an industrial scale.
Each technology is unique, offering its own advantages and disadvantages. The selection of the appropriate technology should be based on actual on-site conditions. Factors such as renewable capacity utilisation factor (CUF), electrolyser ramp-up time, efficiency, system cost, footprint, auxiliary support, and many other considerations must be taken into account before deciding on the choice of electrolyser for producing green hydrogen.
 

Alkaline water electrolysis is the most mature water electrolysis technology available to date, having been in use for over a century. Pioneering green hydrogen projects in the 1920s utilised AWE technology. Numerous companies around the world are currently manufacturing AWEs. This technology is also beneficial for electrolysing brine or saltwater to produce caustic soda, a crucial intermediate in the chlor-alkali industry.

Some of the benefits of AWE are:

  1. Mature, commercialised, and proven technology which has been in existence for over 100 years.

  2. Cheaper system cost ($800-1000/kW) owing to minimal usage of precious Platinum Group Metals (PGMs).

  3. Suitable for continuous or baseload operation like hydropower, geothermal etc. (though some new-generation AWEs can have a high ramp up rate to match the renewables).

Some of the disadvantages of AWE are:

  1. High startup time (~60 minutes) during a cold start.

  2. Hydrogen available at atmospheric pressure (though new generation of Pressurised alkaline water electrolysers (PAWE) can offer a ~40 bar pressure).

  3. Purification system, especially lye separator needed to purify hydrogen.

  4. Bulky equipment, unsuitable for compact applications

PEM is a relatively new technology, having been commercialised about 20-30 years ago. PEM electrolysers offer to reduce some of the disadvantages associated with alkaline electrolysers in terms of size, flexibility towards variable renewables or VRE. PEM is the next most dominant electrolyser technology after alkaline in terms of manufacturing facilities dedicated to this. 

Some of the benefits of PEM are:

  1. Commercialised, and newer technology which has been in existence for about 20-30 years.

  2. Accommodates variability in RE due to its faster response time.

  3. Can be started from cold condition to 100% load in a matter of a few minutes

  4. Compact and suitable for applications having size constraints like automotive hydrogen refueling stations.

  5. Provides hydrogen output at higher pressure (~50 bar).

  6. Provides a very high degree of purity of hydrogen (~99.99% and more purity).

Some of the disadvantages of PEM are:

  1. Expensive (~$1400/kW) due to the usage of PGMs

  2. Highly sensitive to catalyst poisoning due to the slightest entry of impurities in water

SOEC is a new technology in pre-commercialisation phase. This technology offers the highest efficiency of electrolysis, reaching as high as 90% efficiency levels. This technology uses zirconia based ceramics for high temperature steam electrolysis to produce green hydrogen.

Some of the benefits of SOECs are:

  1. Very high efficiency (~90%)

  2. Suitable for operations involving the availability of waste heat, like nuclear, geothermal, etc.

  3. Can reduce even CO2 to CO, which may further be used as a raw material for methanol, ethanol and SAF production.

  4. Suitable for combusting methane or natural gas efficiently and producing a higher electrical output as compared to traditional use involving IC engine or turbine.

  5. Can work reversibly as a fuel cell as well.

Some of the disadvantages of SOECs are:

  1. Expensive (~$2000/kW) due to the nascency of the technology (though this may reduce during widespread manufacturing of SOECs)

  2. Suitable only for processes involving waste heat availability.

  3. Takes several hours during a cold start. Hence, it’s preferable to keep SOECs continuously running.

  4. Extended baseload high temperature operations at 500-600OC range may cause thermal stresses on the sub-components and may negatively affect durability.

AEM is a new technology in pre-commercialisation phase, which combines the good features of both AWE and PEM. This technology neither uses expensive PGMs, nor does suffer from lack of flexibility in case of VRE. 

Some of the benefits of AEMs are:

  1. Cheaper than PEM electrolysers owing to lack of PGMs

  2. Accommodates variability in RE due to its faster response time.

  3. Can be started from cold condition to 100% load in a matter of a few minutes

  4. Compact and suitable for applications having size constraints like automotive hydrogen refueling stations.

  5. Provides hydrogen output at high pressure (~35-40 bar).

Some of the disadvantages of AEM are:

  1. Lack of visibility on price points as the electrolyser technology is quite nascent.

  2. At present, the electrolyser suffers from durability issues when compared with established technologies like AWE or PEM

SUMMARY

Type of ElectrolyserAWE (Alkaline Water Electrolyser)PEM (Proton Exchange Membrane)SOEC (Solid Oxide Electrolyser)AEM (Anion Exchange Membrane Electrolyser)
Key TechnologyMicroporous separatorProton exchange membrane (PEM)Protonic ceramic electrochemical cellAnion exchange membrane (AEM)
Most common electrolyte/membraneNa– or KOH (usually Aqueous KOH of 20–40 wt.%)Proton conductive polymer (e.g. Nafion®) membraneCeramic: Solid, nonporous metal oxide (usually Y2O3- stabilized ZrO2)Anion exchange ionomer (e.g. AS-4) + optional dilute caustic solution
ReactantWater (liquid)Water (liquid)Water (gas)Water (liquid)
Most common electrodes (cathode)Ni & Ni-Mo alloysPt & Pt-PdPerovskite electrodesNi & Ni-Mo alloys
Most common catalystPt and Ru, but also Mn and WPt black, Ir, Ru, RhZrO2Pt and Ru, but also Mn and W
Minimum load (% of design capacity)15–40, 5 (state of the art)0–10 ~5 (typical)>310-20
Operating temperature (deg C)50–8060–200800–100050–60
Average system efficiency (HHV) (%)68–7770–8080–90.8<=74
H2 purity (%)99.5– 99.9999899.9–99.9999~99.9999.99
Estimated stack lifetime (h)~60,000– 100,000~50,000– 90,000   ~20,000– 90,000 ~30,000
Estimated system lifetime (years)20–30 20–30 10–20<20
Approximate investment cost (USD/kW)800–1,5001,400–2,100 >2,000 
System size range (kW)1.8–5,300100–1,3001.5–200>100
H2 production per stack (Nm3 /h)<760<400<10 
Technological maturityMature TRL 9Commercial TRL 7-8R&D TRL 5-7R&D TRL 2-5