Hydrogen Production Through Electrolysis

Abstract

This paper describes the progress of cost reduction activities on a proton exchange membrane (PEM) electrolytic hydrogen generator series at Proton Energy Systems, Inc. (Proton) under cooperative agreement DE-FC36-98GO10341 with the Golden Field Office of the Department of Energy (DOE). Proton's goal is to drive the cost of PEM electrolysis to levels of $600 per kilowatt for 10,000 standard cubic feet per day (scfpd) and $1,000 per kilowatt for 1,000 scfpd of hydrogen gas output. Both of these costs assume a manufacturing volume of 10,000 units per year, and the cost per kilowatt is based on electrical power into the electrolyzer. In addition, this program will evolve the use of PEM electrolysis as an energy storage device to enable renewable technology as a sustainable energy source. Steps to achieve these goals was begun using the HOGEN  (registered trademark of Proton Energy Systems, Inc.) 40 hydrogen generator (1,000 scfpd) platform with aggressive efforts focused on reducing the cost of this unit over the past two years. The plan was to then build on the success of those efforts and apply that learning to the HOGEN 380 generator to leverage the efforts and accelerate the HOGEN 380 generator cost reduction as well. For this past fiscal year, Proton has focused on several aspects associated with these cost reduction efforts. First, all of the previous cost reductions on the HOGEN 40 generator needed to be fully validated by testing to show they would meet the technical requirements of the product and support the customer and market requirements. Second, the control board on the HOGEN 40 was to be advanced into the HOGEN 380 generator product. Third, investigation work was to be conducted on power supply options for the HOGEN 380 generator based on some of the work on the HOGEN 40 generator, but advanced to incorporate the higher power levels required on the larger units. Fourth, cell stack cost reduction activities on compression hardware was to be advanced and cost traded with traditional spring washer approaches. Finally, data was to be collected on renewable power input into a HOGEN 40 hydrogen generator using power conditioning equipment developed on the program. The results achieved over the past two years of the cost reduction efforts for the HOGEN 40 hydrogen generator on this program are in line with the goals of the Department of Energy. Proton projects that the current design of the HOGEN 40 generator projected to 10,000 units per year would be in the range of $1,500 per kilowatt. Furthermore, continuing efforts on materials substitution and design enhancements expected over the next few years should bring the cost of the system to the $1,000 per kilowatt goal for a system of this size. Not only is Proton committed to this cost goal but also to increasing the pressure capability of the system to reduce or eliminate the need for downstream compression of gas. The ability to do this within the $1,000 per kilowatt goal is also within reach and is considered necessary to successfully reaching the $1,000 cost target.