Fraunhofer Institute for Surface Engineering and Thin Films IST
Innovative electrolyzers for the import of hydrogen to Germany
Project ScaleH2
In order to achieve Germany's climate targets, 50 to 70 percent of future hydrogen demand will have to be covered by imports from abroad by 2030. The establishment of international energy partnerships is therefore a core element of the German hydrogen strategy and, at the same time, opens up considerable potential for the export of German hydrogen technologies for the expansion of global production capacities with cost-effective systems for electrolysis.
The successful launch of the hydrogen economy can only be achieved through the economic creation of green hydrogen by means of highly efficient and sustainable electrolysis technologies. In the “ScaleH2” project organized by the German-Australian funding initiative HyGATE, the Fraunhofer IST is working in collaboration with German and Australian partners on, amongst other things, the further development of proton-exchange membrane (PEM) electrolysis. The focus thereby lies on the development and processing of innovative catalyst materials as well as the optimization of the automated production of electrolysis stacks. One key element in reducing investment costs and scaling up the production capacities of commercially available PEM electrolyzers is the reduction of the quantity of platinum and iridium used in the catalysts – without thereby compromising the performance capabilities of the electrolyzers.
Efficient production of electrolysis stacks: innovative coating processes and automation
A fundamental aspect of the project is the process development for the production of the membrane-electrode unit coated with the catalyst material – the main component of the electrolysis cells. Cold plasma spraying, an innovative coating procedure, is hereby utilized in order to process the catalyst produced at the University of New South Wales. Simultaneously, the automation of scalable production procedures in the stacking process for the electrolysis stacks is being further developed in order to enable efficient and economical series production. The implementation and optimization of the automated production of the stacks is performed using the Fraunhofer IST stacking machine at the Hydrogen Campus Salzgitter.
Project overview with respective areas of focus.
Stacking system for automated assembly and disassembly of fuel cell stacks.
Cost analysis and environmental assessment of hydrogen exports from Australia to Germany
The project builds upon the feasibility study conducted by the company ATCO, which investigates the development of an electrolysis capacity of 1 GW in the state of New South Wales as well as the export of green ammonia for the European market. The Fraunhofer IST is thereby modeling the economic feasibilty and potential for cost reduction – from hydrogen production to potential offtakers in Germany.
In addition, the greenhouse-gas emissions along the entire supply chain are being evaluated based on the requirements of the Renewable Energies Directive III for the utilization of hydrogen and hydrogen-based products. In line with the project work carried out by the Fraunhofer IEG, the potential of underground hydrogen-storage facilities in Germany and Australia is also being taken into account.
Outlook
The next important step in the project is the production of the electrode layer using the catalyst material supplied from Australia. Subsequently, the electrochemical characterization and the evaluation of the performance capabilities of the electrolysis cells will be carried out. The fabricated components of the membrane-electrode units and bipolar plates will be used to manufacture the stacks.
This article is part of the Annual Report 2024.