Techno-economic modelling of water electrolysers in the range of several MW to provide grid services while generating hydrogen for different applications: A case study in Spain applied to mobility with FCEVs

The use of hydrogen as energy carrier is a promising option to decarbonize both energy and transport sectors. This paper presents an advanced techno-economic model for calculation of optimal dispatch of large-scale multi MW electrolysis plants in order to obtain a more accurate evaluation of the feasibility of business cases related to the supply of this fuel for different end uses combined with grid services' provision. The model is applied to the Spanish case using different scenarios to determine the minimum demand required from the FCEV market so that electrolysis facilities featuring several MW result in profitable business cases. The results show that grid services contribute to the profitability of hydrogen production for mobility, given a minimum but considerable demand from FCEV fleets.     

Hydrogen production by advanced proton exchange membrane (PEM) water electrolysers—Reduced energy consumption by improved electrocatalysis

Proton exchange membrane (PEM) water electrolysis systems offers several advantages over traditional technologies including greater energy efficiency, higher production rates, and more compact design. Normally in these systems, the anode has the largest overpotential at typical operating current densities. By development of the electrocatalytic material used for the oxygen evolving electrode, great improvements in efficiency can be made. We find that using cyclic voltammetry and steady state polarisation analysis, enables us to separate the effects of true specific electrocatalytic activity and active surface area. Understanding these two factors is critical in developing better electrocatalytic materials in order to further improve the performance of PEM water electrolysis cells. The high current performance of a PEM water electrolysis cell using these oxides as the anode electrocatalyst has also been examined by steady state polarisation measurements and electrochemical impedance spectroscopy. Overall the best cell voltage obtained is 1.567 V at 1 A cm⁻² and 80 °C was achieved when using Nafion 115 as the electrolyte membrane.     

Balancing the grid loads by large scale integration of hydrogen technologies: The case of the Spanish power system

This paper deals with the potential of power generation resources for hydrogen production and electric grid load balancing in large scale management scenarios like the Spanish power system; much of which is currently underutilized and could deliver substantial amounts of energy, with great advantages for the reliability of the system at the same time. In this context, the production of hydrogen by electrolysis using the power grid mix is a promising option as an alternative to other operational procedures or exporting the electricity.     

Production price of hydrogen from grid connected electrolysis in a power market with high wind penetration.

In liberalized power markets, there are significant power price fluctuations due to independently varying changes in demand and supply, the latter being substantial in systems with high wind power penetration. In such systems, hydrogen production by grid connected electrolysis can be cost optimized by operating an electrolyzer part time. This paper presents a study on the minimization of the hydrogen production price and its dependence on estimated power price fluctuations. The calculation of power price fluctuations is based on a parameterization of existing data on wind power production, power consumption and power price evolution in the West Danish power market area. The price for hydrogen is derived as a function of the optimal electrolyzer operation hours per year for four different wind penetration scenarios. It is found to amount to 0.41–0.45 €/Nm³. The study further discusses the hydrogen price sensitivity towards investment costs and the contribution from non-wind power sources.     

Automized parametrization of PEM and alkaline water electrolyzer polarisation curves

A comprehensive literature review of current water electrolyzer modelling research was conducted and presented models critically evaluated. Based on the literature review this paper presents an open-source MATLAB toolbox for water electrolyzer polarisation curve parametrization and modelling. The modelling capabilities of the tooling were verified using measured PEM and alkaline water electrolyzer polarisation data. As real-world measurement data is rarely ideal, tests were also conducted using suboptimal data, first with data sets that have a low number of measurement points and secondly with data sets that have low or high current densities missing. The tooling is shown to work with a wide variety of use cases and provides an automated method for modelling and parametrization of electrolyzer polarisation curves.     

Simulating offshore hydrogen production via PEM electrolysis using real power production data from a 2.3 MW floating offshore wind turbine

This work presents simulation results from a system where offshore wind power is used to produce hydrogen via electrolysis. Real-world data from a 2.3 MW floating offshore wind turbine and electricity price data from Nord Pool were used as input to a novel electrolyzer model. Data from five 31-day periods were combined with six system designs, and hydrogen production, system efficiency, and production cost were estimated. A comparison of the overall system performance shows that the hydrogen production and cost can vary by up to a factor of three between the cases. This illustrates the uncertainty related to the hydrogen production and profitability of these systems. The highest hydrogen production achieved in a 31-day period was 17 242 kg using a 1.852 MW electrolyzer (i.e., utilization factor of approximately 68%), the lowest hydrogen production cost was 4.53 $/kg H₂, and the system efficiency was in the range 56.1–56.9% in all cases.     

WC as a non-platinum hydrogen evolution electrocatalyst for high temperature PEM water electrolysers

Tungsten carbide (WC) nanopowder was tested as a non-platinum cathode electrocatalyst for polymer electrolyte membrane (PEM) water electrolysers, operating at elevated temperatures. It was prepared in thermal plasma reactor with confined plasma jet from WO₃ precursor in combination with CH₄ carburizing agent. The results of the investigation showed that the activity of tungsten carbide as cathode electrocatalyst increases significantly with temperature and this effect is more pronounced than for platinum, especially, at 150 °C.     

An electrochemical study of a PEM stack for water electrolysis

The electrochemical properties of a proton exchange membrane (PEM) stack electrolyzer (9 cells of 100 cm² geometrical area) were investigated at different temperatures. An amount of H₂ of ∼270 l h⁻¹ was produced at 60 A (600 mA cm⁻²) and 70 °C under 876 W of applied electrical power. The corresponding specific energy consumed in the process was 3.24 Wh·l⁻¹H₂. The Faradic and electrical efficiencies were determined. Overall stack efficiencies of 73% and 85%, at 60 A and 70 °C, with respect to the low and high heating value of hydrogen, respectively, were obtained. These results confirmed the successful scale-up of a previous lab-scale device.     

Comparative analyses of a novel solar tower assisted multi-generation system with re-compression CO2 power cycle,thermoelectric generator,and hydrogen production unit

In the present paper, a new energy generation system is suggested for multiple outputs, including a hydrogen generation unit. The plant is powered by a solar tower and involves six different subsystems; supercritical carbon dioxide (sCO₂) re-compression Brayton cycle, ammonia-water absorption refrigeration cycle, hydrogen generation, steam generation, drying process, and thermoelectric generator. The thermodynamic assessment of the multi-generation system is carried out for three different cities from Turkey, Iran, and Qatar. The energy and exergy efficiencies are calculated for base conditions to compare the different locations. The operating output parameters for the suggested system and simple re-compression Brayton system are compared. A parametric analysis is also done for investigating the influences of different system variables on plant performance. According to the results, Doha city is found to be more effective due to its geographical conditions. Moreover, based on the comparative study, the proposed cycles produce more power than the basic re-compression cycle with 64.59 kW, 47.33 kW, and 52.25 kW for Doha, Isparta, and Tehran, respectively. Additionally, the analyses revealed that in the term of energy efficiency, the suggested system has 32.29%, 32.28%, and 32.29% better performance than the simple cycle, and in terms of exergy efficiency, it has 4%, 4.8%, and 5% better performance than the simple cycle in Doha, Isparta, and Tehran, respectively.     

Pressurized PEM water electrolysis: Efficiency and gas crossover

In this study the influence of cathodic and anodic pressures during polymer electrolyte membrane water electrolysis on the gas crossover is simulated and compared to in-situ measurements of the anodic hydrogen content at differential and balanced pressure operation. The efficiency losses due to the reduced Faraday efficiency caused by crossover, ohmic loss of the membrane and pressurized hydrogen and oxygen evolution are estimated. Therefore, the correlated dependencies on the current density, membrane thickness, anodic and cathodic pressures, membrane conductivity and permeabilities are quantified. In addition, pressurized electrolysis is compared to adiabatic and isothermal subsequent compression in focus of efficiency. The outcome of this study can be utilized as a powerful computational tool to optimize the membrane thickness with respect to the operating pressures.     

Performance and cost modelling taking into account the uncertainties and sensitivities of current and next-generation PEM water electrolysis technology

This paper presents a bottom-up approach to the assessment of model performance and costs of a proton-exchange-membrane electrolysis considering cell, stack and process levels. The cell voltage is modelled dependent on current density and detailed models for stack, investment and hydrogen costs are developed. Taking into account current research on PEM electrolysis, such as the use of thinner membranes or low precious metal loading on the electrodes, allows the prediction of next generation's efficiency and costs. By comparison of a current and next-generation PEM electrolysis, the effectiveness of individual development steps was assessed and remaining space for efficiency and cost improvement was identified. This can help to prioritize and to focus on development steps which are most effective.In the next generation, efficiency will be increased even at higher current density operation. Thus, specific stack costs will drop to less than half of present day costs which is decisive to achieve lower hydrogen production costs in the next generation. Specific installed costs and hydrogen production costs of the current and next generation are calculated for plant sizes up to 100 MW_DC and reveal significant cost decrease for plant capacities up to 25 MW_DC while only changing slightly for capacities larger than this.Costs are always subject to uncertainties due to model assumptions and boundary conditions that need to be defined. Uncertainties and the sensitivities of the model are estimated and assessed to provide an indication of the actual cost range. Main cost model uncertainties are identified to arise from membrane electrode and stack assembly costs, civil engineering and construction surcharge as well as the electrical system. Hydrogen costs are dominated by operating costs and therefore are highly sensitive to the annual operating hours and the electricity price, which have a greater impact on the hydrogen costs than the model assumptions for capital costs.     

Evaluation of carbon-supported Pt and Pd nanoparticles for the hydrogen evolution reaction in PEM water electrolysers

Carbon-supported Pt and Pd nanoparticles (CSNs) were synthesized and electrochemically characterized in view of potential application in proton exchange membrane (PEM) water electrolysers. Electroactive metallic nanoparticles were obtained by chemical reduction of precursor salts adsorbed to the surface of Vulcan XC-72 carbon carrier, using ethylene glycol as initial reductant and with final addition of formaldehyde. CSNs were then coated over the surface of electron-conducting working electrodes using an alcoholic solution of perfluorinated polymer. Their electrocatalytic activities with regard to the hydrogen evolution reaction (HER) were measured in sulfuric acid solution using cyclic voltammetry, and in a PEM cell during water electrolysis. Results obtained show that palladium can be advantageously used as an alternative electrocatalyst to platinum for the HER in PEM water electrolysers. Developed electrocatalysts could also be used in PEM fuel cells.     

Development and performance evaluation of Proton Exchange Membrane (PEM) based hydrogen generator for portable applications

This paper presents the development of key components, specifications, configuration and operation characteristics of an 80 l/h Proton Exchange Membrane (PEM) water electrolyzer system for portable application. The developed PEM water electrolyzer can produce 80 l/h hydrogen (purity > 99.99%) with moderate pressure range up to 500 kPa (73 psi) at an operating current of 100 A with energy efficiency of 77.48%. The reliability in operation of developed PEM water electrolyzer system is tested for running the stack about 3000 h with 100 A current. The results indicate the reasonable stability of MEA fabrication and cell design method.     

Comparative performance analysis of PEM and solid oxide steam electrolysers

This paper presents a comprehensive overview of comparative performance characteristics of proton exchange membrane (PEM) and solid oxide steam (SOS) electrolysers based on a thermodynamic analysis. The main factors which influence electrolyser energy and exergy efficiencies were temperature, summation of overpotentials, applied voltage, and to a lesser extent pressure. It is found that anodic overpotentials make up a majority of the total overpotentials in both electrolyser types studied and therefore further development of catalysts to reduce the overpotentials was recommended.     

Prospects for alkaline zero gap water electrolysers for hydrogen production

This review makes the case for cheaper and more efficient water electrolysis technology. In particular, the potential advantages of zero gap, alkaline water electrolysers based on hydroxide ion conducting membranes are highlighted. Following a brief introduction into the thermodynamics and kinetics of water electrolysis, recent developments in oxygen evolving anodes, hydrogen evolving cathodes and hydroxide transporting membranes appropriate to such technology are reviewed.     

Impact of porous transport layer compression on hydrogen permeation in PEM water electrolysis

Gas permeation through a membrane electrode assembly (MEA) is an important issue in the development of polymer electrolyte membrane (PEM) water electrolyzers, because it can cause explosions and efficiency losses. The influence of operating pressure, temperature and MEA modifications on the permeation was already investigated. However, most of the studies pay no attention to the compression of the porous transport layer (PTL) of the MEA when assembling it in a test cell to carry out the experiments.This paper deals with the impact of the PTL compression on hydrogen permeation and cell voltage. Polarization, impedance and permeation measurements are used to demonstrate that the compression significantly affects the MEA's properties. Measurements show either a linear or nonlinear correlation between current density and hydrogen permeation, depending on the compression.The results indicate that the compression of the PTL must be taken into account for developing MEAs and comparing different permeation measurements.     

Response behaviour of proton exchange membrane water electrolysis to hydrogen production under dynamic conditions

Hydrogen production via proton exchange membrane water electrolysis (PEMWE) coupled with renewable energy sources is gaining considerable attention due to its high current densities and flexible responses. This study investigated the voltage responses of PEMWE under dynamic conditions. Three comprehensive performance parameters were adopted to determine the response behaviours of PEMWE devices, including the total response time (TRT), the voltage stability (V_max - V_min), and the difference between the voltages seen for dynamic and static conditions (ΔV = V_dynamic - V_static). The obtained results showed that with small step currents (ΔI = 1 A) and low currents (I < 9 A), PEMWE presented better responses. The TRT was less than 30 s, (V_max - V_min) was less than 10 mV, and ΔV was less than 20 mV. Increasing the amplitude of the step current increased the response time and reduced the voltage stability during electrolysis. The Joule heat produced by the inner resistance have been responsible for the different response behaviours of the PEMWE devices. A durability test showed that after a square wave operated for 300 h, significant degradation of the PEMWE response was observed by comparing the voltage response parameters. Electrochemical characterization studies indicated increases in the static voltage, resistance, and Tafel slope, which were consistent with the degradation of the PEMWE response.     

A comparison of cathodes for zero gap alkaline water electrolysers for hydrogen production

Selected coatings on nickel or stainless steel micromeshes have been examined as electrocatalysts for hydrogen evolution in conditions mimicking those found in zero gap alkaline water electrolysers. Voltammetry in 4 M NaOH at a temperature of 333 K, shows that Pt, NiMo and RuO₂ are the coatings of choice giving a superior performance particularly at higher current densities. NiMo and RuO₂ coatings also give stable performance during a 10 day electrolysis in a laboratory, zero gap, alkaline water electrolysis cell with a hydroxide conducting membrane; when combined with a NiFe(OH)₂ coated anode, a current density of 1 A cm⁻² is achieved with a cell voltage of ∼2.1 V. Pt catalyses H₂ evolution efficiently at short times of electrolysis but cells with a Pt cathode show an increase in cell voltage from 2.05 V to 2.23 V during the first two days of operation.     

Tantalum carbide as a novel support material for anode electrocatalysts in polymer electrolyte membrane water electrolysers

Iridium oxide (IrO₂) currently represents a state of the art electrocatalyst for anodic oxygen evolution. Since iridium is both expensive and scarce, the future practical application of this process makes it essential to reduce IrO₂ loading on the anodes of PEM water electrolysers. In the present study an approach to utilising a suitable electrocatalyst support was followed. Of the materials selected from a literature review, TaC has proved to be stable under the conditions of the accelerated stability test proposed in this study. The test involved dispersing each potential support material in a mixture of trifluoromethanesulfonic acid (TFMSA) and hydrogen peroxide at 130 °C. The liquid phase was subsequently analysed using ICP-MS with respect to the occurrence of ions potentially originating from the support material tested. The TaC support selected was additionally characterised by thermogravimmetric and differential thermal analysis to prove its thermal stability. A modified version of the Adams fusion method was used to deposit IrO₂ on the support surface. A series of electrocatalysts was prepared with a composition of (IrO₂)_x(TaC)_1−x, where x represents the mass fraction of IrO₂ and was equal to 0.1, 0.3, 0.5, 0.7, 0.9 and 1. The thin-film method was used for electrochemical characterisation of the electrocatalysts prepared. SEM–EDX analysis, X-ray diffraction, N₂ adsorption (BET) and powder conductivity measurements were used as complementary techniques to complete characterisation of the electrocatalysts prepared. The electrocatalysts with x ≥ 0.5 showed stable specific activity. This result is consistent with the conductivity measurements.