New cell and stack design developed for electrolyzers

Within the framework of the CINES Dimension Electrolysis, Fraunhofer ISE researchers have developed and patented an advanced cell and stack design for electrolysers. This novel half-cell composite (HZV) reduces the material and manufacturing costs for PEM electrolyzers and thus enables large-scale mass production. Fraunhofer ISE, ICT and UMSICHT are collaborating in the CINES Dimension Electrolysis. Fraunhofer ISE will present this half-cell composite along with other innovations for the hydrogen economy from April 17 to 21, 2023 at the Hannover Messe in Hall 13, Booth D35.

© Fraunhofer ISE
Novel half-cell composite for a PEM electrolysis cell, consisting of a porous base element, metal mesh, a porous transport layer, and an inserted joining compound of elastomer to form the sealing and channel structures.

In order to be able to produce competitive stacks for PEM electrolysis in high volumes in the near future, innovative steps are required in both design and manufacturing. The half-cell composite (HZV) developed at Fraunhofer ISE now combines the functionality of the individual components of conventional designs, such as the surround, sealing element, channel structures for media supply and porous transport layer, in just one component - but without using an additional frame part. The advantages of using the half-cell composite are manifold: it reduces material and manufacturing costs, reduces the number of components and thus simplifies assembly. In addition, this offers new possibilities such as area scaling, automated manufacturing processes and simplified quality inspection of a half-cell composite before assembly.

Without frame part to simplified assembly: positive results of the feasibility analysis

On an area of 150 cm2 , the researchers were able to demonstrate that the half-cell composite is capable of withstanding pressure and temperature cycling loads on the anode and cathode, respectively, of up to 10 bar and 80°C in operation without any significant loss of performance. Based on these positive results of the feasibility analysis, a patent application was filed for the developed design and manufacturing process. Currently, a scaling to larger cell areas up to 600 cm2 with higher hydrogen gas pressure is aimed at in order to achieve an industrially relevant design with comparable power densities as in the feasibility analysis.

Hydrogen and its derivatives are an important pillar in a sustainable global energy trading system, as they can store large amounts of energy over long periods of time. They can also be transported in ships or pipelines and used in the near future to replace fossil fuels in all energy-consuming sectors. In addition, hydrogen is the basic molecule for the production of renewable synthetic fuels or chemicals. By electrolysis, water is split into hydrogen and oxygen using electricity; proton exchange membrane electrolysis (PEM) is characterized by a dynamic mode of operation, so that it can be flexibly operated with electricity from renewable sources. Fraunhofer ISE has been working on various design and production engineering issues related to PEM electrolysis for 30 years.

Innovations for the hydrogen economy from April 17 to 21, 2023 at the Hannover Messe in Hall 13, Stand D35

Other innovations will be presented at the Fraunhofer ISE booth at the Hannover Messe: For example, a membrane electrode unit for PEM fuel cells produced by the decal process with catalyst layers produced by the screen-printing process can be seen. The Institute's researchers will also show the characterization of cell components and lifetime tests using a test fuel cell and a power-to-X cube illustrating the relative energy density of different hydrogen-based energy carriers compared to unpressurized, compressed as well as cryogenic liquefied hydrogen.

Fraunhofer ISE researchers will also provide insight into their work during public lectures and discussions at the exhibition center.

Hydrogen Towards Net Zero Pathway

  • Prof. Dr. Christopher Hebling, Director Division Hydrogen Technologies, Fraunhofer ISE
  • April 17, 15:00-15:20, Public Forum, Hall 13, D 25
  • The future energy supply will rely on green energy as its foundation. Nevertheless, renewable sources face challenges such as seasonal fluctuations in energy production and imbalances between production and demand. In an upcoming presentation, Prof. Dr. Christopher Hebling will demonstrate how hydrogen and its derivatives can effectively address these gaps, playing a crucial role in our journey towards achieving a net zero society.

Green Hydrogen Production & Electrolyzers

  • Dr. Tom Smolinka, Head of Department Chemical Energy Storage, Fraunhofer ISE, Dr. Sean Mackinnon, Chief Scientist, Loop Energy
  • April 17, 17:00-17:15, Technical Forum, Hall 13, B 51

Discussion: Next Generation Electrolysers

  • Sebastian Kopp, Research Associate Electrolysis Group, Fraunhofer ISE, Dr. Isabel Kundler, Senior Advisor Electrochemistry, DECHEMA, Jan-Justus Schmidt, CTO/MD, Enapter, Dr. Frank Meyer-Pittroff, Head of Components & Modules, R&D Hydrogen, Schaeffler
  • April 19, 14:00-14:40, Public Forum, Hall 13, D 25

Learn more about our work in the field of electrolysis here. Contact us or write us.