High Efficiency
Large PEM
Electrolyzers
Timothy Norman
VP of Engineering
Giner,
Inc.
89 Rumford Ave,
Newton, Ma. 02466
Hall 27, C 40
Outline


Giner, Inc. Overview
Advancements in Efficiency

New Membranes
Performance & Efficiency
 Lifetime
 Durability


Cost Reduction
Innovative Stack Designs
 High Pressure Electrolysis
 Performance & Validation



Large Scale PEM Electrolyzer
Wrap-Up
2
GINER, Inc.
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Giner, Inc. Founded in 1973
Specializing in research & development
of PEM based electrochemical
technology and systems
Since 2005 Giner has accelerated
growth

Key driver has been the
manufacturing of PEM electrolyzers
to OEMs

Global leader in Polymer Electrolyte
Membrane (PEM)-based
electrolyzers

Highest efficiency technology for
commercial applications
Core Mission: Provide Innovative PEM
Technologies with the Highest
Efficiencies at the Lowest Costs to
Developing Hydrogen Markets
Staff:
65 people
Facility 25,000 sq ft +
Synergy of Giner, Inc.
Technologies
3
Giner Electrolyzers
Electrolyzer Stacks
Electrolyzer Systems
Vehicle Applications
Differential
Pressure
Balanced
Pressure
Anode Feed
Cathode Feed
Vapor Feed
On-Site H2
Generators
Laboratory
Hydrogen
Static Feed
Regenerative
(Combined Fuel-Cell
& Electrolyzer)
Electrochemical
H2-Compressors
Life Support
Oxygen
Concentrators
4


Giner, Inc. Overview
Advancements in Efficiency

New Membranes
Performance & Efficiency
 Lifetime
 Durability


Cost Reduction
Innovative Stack Designs
 High Pressure Electrolysis
 Performance & Validation



Large Scale PEM Electrolyzer
Wrap-Up
5
Membrane Development
Giner Dimensionally
Stable Membranes (DSMTM):
High-strength,
High-efficiency membranes
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PFSA ionomer incorporated in an engineering
plastic support (2D & 3D)
 Superior Mechanical Properties
 No x-y dimensional changes upon wet/dry
or freeze-thaw cycling
 Stronger Resistance to tear propagation
 Superior to PTFE based supports, 10x
stronger base properties
Membranes optimized for ionomer EW and
thickness
Enabling technology for high pressure
applications
Role to role process underway
Commercial viability in 2015/16
Laser-Drilled
3D Substrates
Chemically Etched
Cast
Membrane Supports
R&D funded
U.S.
Department
of Energy
6
Membrane Efficiency
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Demonstrated high
efficiency DSM
membranes in single-cell
and large multi-cell stacks
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Cell voltage efficiency up to
90%(HHV),
44.0 to 47 kWhe/kg-H2 @
1500 mA/cm²
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MEAs utilize low-loaded
catalyst loadings (reduced
by 90%)
Nafion is a registered trademark of E.I. du Pont Nemours and Company
7
Membrane Lifetime
Scaled-up Membrane Performance
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Demonstrated 5,000+ hrs lifetime of scaled-up DSM
membrane at 80C
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DSM MEA from 5-cell short stack re-assembled into
a single-cell stack, total testing time = 5,430 hours
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Efficiency: up to 88% (HHV) @ 1500 mA/cm²
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Scaled-up testing includes low-cost stack
components
Membrane Degradation (Estimated Lifetime)
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F ion Release Rate: 3.7 µg/hr (<10 ppb)
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DSM -1100EW (Stabilized Ionomer): ~55,000
hours
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Membrane Durability
Membrane Degradation (Estimated Lifetime)
Performance Under Aggressive Conditions
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Demonstrated high current density (5,000 mA/cm²)  Advanced DSM: Improved membrane stability at
and high pressure (5,000 psig) operation
high operating current density
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Operated 4-Cell stack at 5,000 mA/cm² for 1,000
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Low degradation enables longer operation at
hours
 DSM operated at 10,000 mA/cm² (in continuous 24 higher temperatures
hour test)
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Advanced DSM with proprietary additive
mitigates degradation and improves life at high
operating current densities
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Stack Efficiency Vs. Cost of H2 Production
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Hydrogen production cost dominated by feedstock
 Feedstock is largest $ contributor
Efficiency is key to cost competitiveness!
Larger benefit for MW Scale
Feedstock
H2 Forecourt Station
H2 Production
Cost Component Breakdown
10


Giner, Inc. Overview
Advancements in Efficiency

New Membranes
Performance & Efficiency
 Lifetime
 Durability


Cost Reduction
Innovative Stack Designs
 High Pressure Electrolysis
 Performance & Validation



Large Scale PEM Electrolyzer
Wrap-Up
11
Stack Advancements & Cost Reductions
Stack Improvements
Repeating
Cell Unit
Fluid End Plate
Negative Terminal
30 to 90
Nm3/hr
Cell Separator
Anode Support Mat’l
Cell Frame (O2)
MEA
Cathode Support Mat’l
Cell Frame (H2)
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Positive Terminal
End Plate
The repeating cell unit comprises 90% of electrolyzer stack cost
Part Count
Required to
Generate
1500 kgH2/day
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>60% Stack Cost Reduction
Increased active area (2x)
Reduced catalyst loadings by 90%
Implemented new manufacturing
techniques
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Molded Thermoplastic
Components
Improved Cell-Separators: Lifetime >
60,000 hours
Material requirements reduced by
30%
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Reduced Cathode & Anode
Support Mat’l
Alternative low cost materials utilized
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Reduced non-repeater costs
>50%
Reduced Part Count from 41 to 10
Parts/Cell-50% labor reduction
Commercialized Electrolyzer
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1st to market with 47 kWh/kg
stack @ 1700 mA/cm²
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Rapid market penetration
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Product sold in 7 Countries
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Product exclusively used in
renewable
energy
applications

Compliant
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Improving Pressure Capabilities of PEM Electrolyzers
Advantages of High Pressure
PEM Electrolysis
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Eliminates one or more stages of
mechanical compression
Reduces system complexity
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Hydrogen at
5,000 psig
(350 Bar),
Ambient O2
Generated
directly in PEM
Electrolyzer
Lower drying requirements
Low maintenance
No moving parts
 No contaminants
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Cross-cutting technology, applicable to
Electrochemical Hydrogen Compressors
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Permits hydrogen generation at user endsite
DSMTM Enabling Technology
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High Pressure Electrolyzer Systems
Increasing electrolyzer pressure leads to
system simplification, but remaining
challenges exist:
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Higher cost BOP components
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Innovative system component
development required
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Extended durability testing/validation
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Hydrogen dryers
Gas-phase separators
Level sensing
Full optimization studies
Increased back diffusion
 R&D program initiated to develop
new ionomers with reduced gas
permeation
FCV Home Refueling
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Validation at National Renewable Energy Laboratory
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System Validated at NREL in June 2012
Nominal operating conditions: 390 psig (27 bar),
1500 -1900 mA/cm²
High stack voltage efficiency: >87% HHV; Energy
efficiency;46.6 kWhe/kg-H2
Stack Efficiencies in line with DOE 2012 Targets
Development of low-cost high-efficiency components
Hydrogen drying losses: ~3% (Industry: 10%)
Giner Stack Efficiency
~87.5%
@ 1500 mA/cm²
NREL Report: Milestone 3.7.6 (CPS 52066)
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Electrolyzer Stack Validation
Third Party Validation
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Giner commercial electrolyzer
stack in-use at Areva Site
 Operating at multiple sites
 Customer confirms 2,000
hours at 47 kWhe/kg
1,700 mA/cm²
AREVA’s energy storage platform
‘GREENERGY BOX’
in Corsica, France Utilizing GES Low-Cost
Electrolyzer Stack
Modular RFC systems
with energy storage
from 0.2 to 2MWh
16


Giner, Inc. Overview
Advancements in Efficiency

New Membranes
Performance & Efficiency
 Lifetime
 Durability


Cost Reduction
Innovative Stack Designs
 High Pressure Electrolysis
 Performance & Validation



Large Scale PEM Electrolyzer
Wrap-Up
17
Large Scale Electrolysis Led by Market Demand
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Market Drivers
 U.S. National Defense Authorization Act of
FY2007/FY2010:
 DoD must produce 25% of total energy
from renewable energy sources by 2025
 European Commission1
 2020 Strategy: 20% share of renewable
energy in EU energy consumption, with a
10% share in transport
 2050 Roadmap calls for a 55 - 75%
share of RES in gross final energy
consumption, 80% reduction in green
house emissions
Next step:
>220 Nm3/hr
(MW Scale)
1http://ec.europa.eu/energy/energy2020/roadmap/doc/com_2011_8852_en.pdf
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Target markets require larger electrolyzer
stacks and systems
 Intermittent Renewable Energy Source
(RES) integration
 Backup power for grid outages and load
shedding
 Mobility
 Power to Gas
30-90 Nm3/hr
2-3 Nm3/hr
0.05 Nm3/hr
18
MW Scale PEM Electrolysis
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Increased system output requires larger
stacks to be competitive
In-house program initiated to develop
MW Scale electrolyzer
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Large scale stacks previously
designed and manufactured
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MW stack design leverages work
developed on earlier stacks
 Reliability, Efficiency, Cost,…
220 Nm3/hr
MW
Electrolyzer
19


Giner, Inc. Overview
Advancements in Efficiency

New Membranes Coming to Market
Performance & Efficiency
 Lifetime
 Durability


Cost Reduction
Innovative Stack Designs
 High Pressure Electrolysis
 Performance & Validation



Large Scale PEM Electrolyzer
Wrap-Up
20
Summary
 Giner’s capabilities continue to grow to meet new market demands
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Increase efficiency

High pressure electrolysis stacks & systems
 New membrane development
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Mobility and storage
Increased hydrogen output
 MW scale PEM electrolyzer
 Efficiency is Key to Competitiveness

Giner commercial PEM Electrolyzers exceed market performance
 High stack efficiencies and improved durability reduce overall operating
costs
 Reduction in Capital Cost achieved by implementing innovate stack
designs

PEM Electrolysis is a mature technology that is highly cost competitive
21
Thank You!
VP of Engineering
Timothy Norman
mhamdan@ginerinc.com
+1 781 529 0526
Business Development
Hector Maza
hmaza@ginerinc.com
+1 781 529 0589
www.ginerinc.com
Hall 27, B66
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