Low-Cost Manufacturing of High Temperature Electrolysis Stacks

Dr. Scott Swartz, Nexceris’ Founder and CTO, presented an update on the Low-Cost Manufacturing of High Temperature Electrolysis Stacks at the DOE Hydrogen Program: 2022 Annual Merit Review and Peer Evaluation Meeting held on June 6-8, 2022.

What follows is a summary of the presentation.

The project goal is to develop cell and stack manufacturing technologies to enable an elevated temperature electrolysis stack manufacturing cost of less than $100 per kW.

Nexceris’ FlexCell^TM

·      A two-layer membrane mesh layer that mechanically supports a thin electrolyte membrane

·      A thin membrane for improved performance

·      The Dense cell periphery facilitates sealing

·      Electrode material for process flexibility

Cell Cost Reduction

·      Scale-up production of advanced barrier layers and oxygen electrode materials

·      Reduce thicknesses of FlexCell^TM support and membrane layers to increase active cell area

Nexceris’ FlexStack^TM

·      Stack components designed for low-cost manufacture

·      External air manifolding scheme simplifies egress of oxygen effluent into ambient

·      Large active cell area enables appropriate stack module size for megawatt-scale HTE systems

Stack Cost Reduction

·      Validate low-cost interconnect alloy material

·      Long term stack durability testing

·      Reduce number of components in stack repeat unit

·      Automation of stack component manufacturing

Successful execution of this project will enable elevated temperature electrolysis stacks to be manufactured at a cost of $100 per kW, which is required to achieve DOE’s Earth Shot goal of producing hydrogen at $1/kg.

Please click here to review the full presentation.

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