PEM & Alkaline Electrolyzers Bottom-up Manufacturing Cost Analysis , Fuel Cell Seminar 2014 ...

20 Pages·2016·0.71 MB·English

PEM & Alkaline Electrolyzers Bottom-up
Manufacturing Cost Analysis

Yong Yang David Hart
Austin Power E4tech
November 10, 2014
E4tech
Austin Power Engineering LLC
Av. Juste-Olivier 2
1 Cameron ST
1006 Lausanne
Wellesley, MA 02482
Switzerland
USA

Tel: [phone]
www.AUSTINPOWERENG.com
[email protected]
[email protected]
www.e4tech.com
Introduction Objective
The objective of the study is to understand the cost reduction potential of the
main water electrolysis technologies
Water electrolysis could become an important part of
future stationary energy and transport systems
Where and how it could play a role depends on the
cost reduction that could be achieved in moving
from a small and unoptimised industry
Detailed modelling can provide insight into both
ultimately achievable costs and the impact of certain
design choices and technology improvements
2014 YY/DH 1
Introduction Market Overview
Water electrolysis could play a significant role in the future energy system, if
predicted cost reductions can be realised.
Consolidated views on rollout potential

Roadmap for

electrolyser
deployment by

application.
Source:
2014 FCH-JU study on

water electrolysis
Expert ‘predicted’ cost reductions
Data source cost
reduction expectations:
2014 FCH-JU study on
water electrolysis
2014 YY/DH 2
18%
Introduction Market Overview
30%
4%
Today’s electrolyser market is comparatively small, the industry landscape is
18%
highly fragmented and no single design dominates 30%
4%
• Perhaps 4% of global hydrogen supply is 48%
produced via electrolysis 18%
48%
30% Coal gasification
18%
• Larger (> 50 kW) water electrolysis systems 4% Electrolysis
30% Coal gasification
Natural gas reforming
are typically deployed for continuous operation. 4% Electrolysis
ReNfiantuerrayl g/aCsh reefmormiciangl off-gases
Examples are fertilisers and methanol Refinery/Chemical off-gases
production, fats & oils, float glass, …
48% 48%
SouSorucrec:e :I EIEAA ((2200070)7)
• The industry is highly fragmented, with a few
Coal gasification
established players and many start-ups / new Coal gasificaEtlieocntr olysis
Natural gas reforming
Electrolysis
entrants – and cost reduction potential Refinery/Chemical off-gases
Natural gas reforming
Refinery/Chemical off-gases
Chemistry Parameter (Examples) Design philosophy options Implications (Examples)
PEM Cell size Small cell versus large cell approach Component material choice, fewer stacks
PEM Cell pressure design Balanced versus unbalanced pressure System control, gas purification
Alkaline Liquid-gas separators Stack-internal versus external Cell material usage efficiency
Alkaline Operational pressure Pressurised versus unpressurised design Cell material choices, gas purification
2014 YY/DH 3
Introduction Technology Overview
Overview of key performance indicator of state-of-the-art electrolyser
technology.
Parameter Unit Commercial alkaline Commercial PEM
Stack capacity kW 200 – 4,500 40 – 100
System capacity kW 1,100 – 5,300 100 – 1,200
Specific electricity input (system, nominal kWh/kg 50 – 78 50 – 83
H2
load)
Hydrogen output pressure bar(g) 0.05 – 30 10 – 30
Stack lifetime (continuous operation) hours 60,000 – 90,000 20,000 – 60,000*
System lifetime (continuous operation) years 20 – 30 10 – 30
Current density A/cm² 0.2 – 0.4 1.0 – 2.0
Overload ability % Currently not more than 20% offered commercially,
el
though PEM could ultimately have 200% – 300%
Operating temperature °C 60 – 80 50 – 80
Minimum part load % 20 – 40 5 – 10
el
Specific electricity input (system, variable kWh/kg No manufacturer data available. At stack level specific
H2
load) electricity may reduce by 2 to 5 kWh/kg at 50% of
nominal electric load
Responsiveness (ramp time) % /second 0.1 – 10 10 – 100
el
Start-up time cold & pressurised / cold & unpressurised >20 minutes / several ~5 / ~15 minutes
hours
2014 YY/DH 4
Approach Manufacturing Cost Modeling Methodology
This approach has been used successfully for estimating the cost of various
technologies for commercial clients and the DOE.
Technology Manufacturing Scenario Verification &
Assessment Cost Model Analyses Validation
• Literature research • Define system value • Technology scenarios • Cost model internal
• Definition of system and chain • Sensitivity analysis verification reviews
component diagrams • Quote off-shelve parts • Economies of Scale • Discussion with
• Size components and materials • Supply chain & technical developers
• Develop bill-of- • Select materials manufacturing system • Presentations to project
materials (BOM) • Develop processes optimization and industrial partners
• Assembly bottom-up • Life cycle cost analysis • Audition by
cost model independent reviewers
•Develop baseline costs

100%PurGchDaLse1d0 0% 7800,, 000000 PFuElMl BFaCtt ePrlyu gE lHecybtrricid V Veehhiciclele Stack AssemblyConS2dt.ia7tic%okn inMgembrane
99.9% 98.5% 6.3% 8.0%
Balance of Stack
100% 100% Pt AnInokde 99%CAatnaolydset SLaid9ye8e.r5% 100% 98.5% )$( pihsrew5600,,000000 8S.e4a2%l.4%
110000%% 110000%% INoPnaotfimone®r 9C9%aItnhkode 98.5% 99CC%aaMPttahrleooymdcseetb sLrSsaaeyin9dsee8er.5% LHaomt iPnraetsiosn O fo tsoC latoT234000,,,000000000 Bipolar Plate El4e1c.t0ro%de
10,000 26.1%
99.9% 98.5%
Purchased
GDL 0 GDL
100% 100% 3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO 5.1%
2014 YY/DH 5
Approach Manufacturing Cost Modeling Methodology
Combining performance and cost model will easily generate cost results, even
when varying the design inputs.
Conceptual Design Process Simulation Process Cost Calcs
Air (POX only) 99.99% pure H2 Compressor with intercoolers $10
Nat. Gas ReFfouremler PSA CTooowlienrg $$89 MPraotceerisasl
Water H2-rich gas $7
CH2OO2 HeaCtBautarnlyetirc H2-poor gas CWoaldter )$( tsoC refaW$$$456
$3
To Vehicle PSrteLocFsonlrotsarwwlrugree PMSrteeocFsdnrlostiarwulurgmree PSrtHeocFsinlrgotsarwlhrugree $$12
Dispenser $0LappingWet theCrMmPal OxidatioSnpin CoWaetti nEtgching DSiC OS2putterinRg F NiSputtering SEpin CoatingStDepC pSerputtering AgStrippinSgpin CoatingSteDrpyp eErtching SiO2DRWIetE EStiching SiDOr2y Etching NI
System layout and Energy requirements Process cost
equipment requirements Equipment size/ specs Material cost
Site Plans Capital Cost Estimates Product Costs
NG line inHC2a sHciSagdyhse Pt eSrmetosrsaugreeSecurity Fence Fuel Station Perimeter 7800,,000000 PFuElMl BFaCtt ePrlyu gE lHecybtrricid V Veehhiciclele
CasCcNaGde H Sigtohr Pagrees Ssyusretem UnderFgirroeu Dnedt ePcCitpooivnregr ewdit hF usehlainrDgedi sIGs pclaaoesnnnedsdoiunuigts IFsulaenldVsent Building APnToSaowAlpidpdnee o CeCrd aPeasrstetp ESlmEeVPlSaecSaPPllccalpt crrtrPsrrueerionmaooueptlymwynaltydeteer FaBblSarlniickciinnaggt i/on Sin1t4e0r 0inC Air InItnetQFeCrroCcchr oomLeofnecinnnkaegknctectCSInamtCVePtSaSSrhaaPPllccalhp ctorrorPhseueerinonmaouadepntdywmrnaeeedcetr ISPntiaenirtnocetnor B tnionrna eAzciert FiniBshra Ezedges )$( pihsrewO fo tsoC latoT2345600000,,,,,000000000000000
EleHcCtirgoohmly-Ppzrereers sossruo SrreMR, TaskC 15u0 Cp6eN1Pr TGtrDioIn/AeHp1o Xye0A,d r CnLtfrytozLA agoC 9 efB:5nl0 vF1du4.elingSCSAAIZLEESte1fa"HD n=W y UG8dn SBfntYraiotsecgh ePnl aa5nn J da-n C F20Nu04Gel Bifn0u2geD2SW8H l EiSG-nE SNTtgO0a0 2ts2itoantio1n OF 1R1EV Slurry SprayNote: bAolttetornmat iovfe a pcrtoudaul pctrioodnu pcrtoiocne pssroecse aspspeesa ars isnu gmraeSSydlp utrroaryy the Stack Assembly 10,0000 3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO
WWBAPSROudutatraahijbeilollledrMllles iiorcinotn ias wifpngnsldaeiii gtd mimnhtn repi taumnmwarcmgoksaakispnetlb sk oesi (mlvsedrreet,a outy gn-pg ombattaehrsas sr afk (c istmr&ek etc od o wadrr ravaniiensetg ib dtnhesaeogitcn wr bloicesnufes) gi2slte hofnoontr ug rhasysd nroogteedn iaf nredl/2511111eo55005050v r f affffffftntttttttnatt)ural g afffffffftttttttts
Safety equipment, site High and low volume Product cost (capital,
prep, land costs equipment costs O&M, etc.)
2014 YY/DH 6
Approach Manufacturing Cost Structure
Austin Power Engineering’s manufacturing cost models can be used to
determine a fully loaded selling price to consumers at high or low volumes.
Profit
Corporate Expenses
• Research and Development
Sales
• Sales and Marketing
Expense
• General & Administration
• Warranty General
• Taxes Expense
Fixed Costs Factory
• Equipment and Plant Expense
Depreciation
Consumer • Tooling Amortization
• Equipment Maintenance Direct
Selling Price
• Utilities Labor
• Building Manufacturing
• Indirect Labor Cost
• Cost of capital
• Overhead Labor
Variable Costs
Direct
• Manufactured Materials
Materials
• Purchased Materials
• Fabrication Labor
• Assembly Labor
• Indirect Materials
We assume 100% financing with an annual discount rate of 10%, a 10-year
equipment life, a 25-year building life, and three months working capital.

2012 YY 7
Approach Scope
Our cost assessment includes four systems which are a current alkaline
system, a future alkaline system, a current PEM system, and a future PEM
system.
Alkaline PEM
Future Future Alkaline
Future PEM System
System
Current Alkaline Current PEM
Current
System System
2014 YY/DH 8
Alkaline System
Alkaline systems are assumed to have the following system and stack designs
in the different scenarios.
Small Cell Large Cell
Alkaline Unit
Current Future
System size kW 1,000 4,000
Stack size kW 250 2,000
Stacks per system 4 2
System Pressure Barg 15 15
H2 Purity % 99.999% 99.999%
Active cell area cm² 3,125 12,500
Cell voltage V 1.75 1.75
Active area / total cell area 25 85
%
(Gas/liquid separation) (internal) (external)
Current density A/cm² 0.4 0.8
Membrane material polyantimonic acid / polysulfone Zirfon
Anode / cathode material Ni foam (plus Ni(OH)2) / Ni mesh Ni foam (plus Ni(OH)2) / Ni mesh
Conductive porous layer Ni foam Ni foam
Cell frame material PPO Polymer SS316
Annual Production Volume 12 MW 1.2 GW
2014 YY/DH 9