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DOE OSTI2025

Membrane Electrode Assembly Manufacturing Automation Technology for the Electrochemical Compression of Hydrogen: Cooperative Research and Development (Final Report)

Electrochemical compression has the possibility to outcompete mechanical compression for hydrogen end- use applications. While HyET has a compressor that can output JO kilograms (kg)/day (fully scalable from home-to-industrial application) at up to 700 bar, the energy demand and reliability require top-quality electrochemical hydrogen compression (EHC) membrane electrode assemblies (MEAs), preferably prepared by cost-effective high-capacity manufacturing. High pressure requires a special MEA design, deviating from typical proton exchange membrane fuel cell (PEMFC) MEAs with adapted catalyst layer substrates, asking for a modified coating process. The National Renewable Energy Laboratory (NREL) will help HyET by developing an automated catalyst coating process fit for EHC MEA manufacturing. In addition, inline quality inspection methods will be developed/selected to improve the MBA quality as it is used for EHC stack assembly. In a joint effort, NREL and HyET will even design an automated manufacturing process for the EHC MEA and approach potential United States (US) suppliers of manufacturing equipment.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Electrochemical Hydrogen Compression Cell Design (CRADA Final Report)

Electrochemical compression and purification is a high potential technology that is likely to outcompete mechanical compression for hydrogen end use applications. However, testing and understanding what is occurring within the cell is difficult as it is not readily accessible through experimentation. Thus, the main target is to increase performance and reduce cost of electrochemical hydrogen compression (EHC) and purification (EHP) cells and stacks using multiscale mathematical modeling informed by experiment. The models can provide physical insight into limiting processes and develop mitigation methods, which can be proven out through rapid sub-scale testing of the devices.

08 HYDROGEN↗

DOE OSTI2023

Hybrid Electrochemical Hydrogen/Metal Hydride Compressor (Final Technical Report)

Various alternatives to traditional mechanical compressor systems have been considered, including MHC and EHC. Both MHCs and EHCs are solid-state systems that have no moving parts other than valves. Both are quiet and have low maintenance requirements. However, strength and material issues as well as water and heat management issues have challenged EHCs, especially, when operated at very high pressures. Similarly, low efficiency, especially, when staging is required to attain high, pressure ratios, has challenged MHCs and has made them too complex and expensive. Material degradation, due to hydrogen impurity effects, has also created issues for MHCs. One novel alternative evaluated here is to combine EHC and MHC technologies in a way to maximize their advantages and to minimize each of their challenges to improve the overall systems performance on a path to meet or exceed current DOE targets. A hybrid EH/MH compressor takes advantage of lower maintenance and operating costs as well as increased reliability associated with both the MHC and EHC technologies over traditional mechanical compressors. Neither the MHC nor the EHC have any moving parts other than valves. The hybrid system also takes advantage of the higher efficiency and lower cost of the EHC by operating at lower delivery pressures combined with the robust and simple operation of a single-stage, MH compressor at higher pressures. Both MHC and EHC technologies are scalable and can be used for a variety of hydrogen compression and delivery applications.

08 HYDROGEN↗

DOE OSTI2020

Advanced Electrochemical Hydrogen Compressor

U.S. automakers have invested significant resources in the research and development of hydrogen fuel cell electric vehicles (FCEVs). However, to enable the widespread deployment of FCEVs, an additional major investment is required to achieve an infrastructure for compressing hydrogen in hydrogen fueling stations. In order to dispense hydrogen to FCEV tanks quickly, the hydrogen must be compressed above a pressure of 875 bar (12,687 psi) at the fueling station. Mechanical compressors currently in use have high maintenance costs, poor reliability, and are noisy. To eliminate the need for mechanical compressors, Plug Power is extending its extensive experience in high-pressure proton-exchange-membrane (PEM), to develop an electrochemical hydrogen compressor (EHC) system for refueling applications that can deliver hydrogen at pressures greater than 875 bar. The work performed during this project was a collaboration between the Nation Renewable Energy Laboratory (NREL), Rensselaer Polytechnic Institute (RPI), and Gaia Energy Research Institute LLC (GAIA).

08 HYDROGEN↗