Condition Monitoring for Increased Longevity, Efficiency and Safety of PEM Electrolysers

Green hydrogen will facilitate a transition from fossile fuels to renewable energy sources. PEM electrolysis is one of the key technologies for conversion of renewable energy to hydrogen and the technology has a large growth potential. The most important aspect for further growth is the reduction of CAPEX and OPEX. The project has the target to improve PEM electrolysis technology by developing and validate advanced condition monitoring of cells and electrolysers. The main goal with the project is to evaluate components through advanced test protocols and measurement methods that are technologically relevant for commerical large-scale electrolysers. Advanced analysis of the lifetime will be done on the tested materials. The project will contribute to an accelerated development of the green energy transition by shortening the time for development projects and support a faster commercialization of competitive electrolysis products.

Proton exchange membrane (PEM) water electrolysis is one of the key technologies for conversion of renewable energy to hydrogen and has a large potential for growth especially in connection with renewable energy sources (RES). Enabling factors to support the growth are reduction in CAPEX and OPEX, including extended lifetime. This can, among others, be achieved through improvements in product design, catalysts, membranes, and optimization of operating conditions. The H2PANACEA project aims to enhance the longevity, efficiency, and safety of industrial-scale water electrolysers, esp. when operated with intermittent RES. This will be achieved through a condition monitoring method that uses naturally available operational data, acting as virtual sensors, combined with advanced data processing algorithms. This innovation will support the development of PEM electrolyser materials by Nel and provide a State-of-Health (SoH) monitoring method for integration into hydrogen plants. To reduce the costs of green hydrogen, Nel Hydrogen is innovating in both PEM and alkaline electrolyser technologies. For PEM, these efforts include advanced electrode manufacturing using roll-to-roll coating processes, optimization of porous transport layers, and significant reductions in membrane thickness. A reliable SoH monitoring tool will support this development by improving the analysis of the materials screening and qualification tests. Being able to offer a condition monitoring system that can be integrated in hydrogen plants will, furthermore, be crucial for Nel in a competitive market because they will gain process control and be able to extend their warranties. Although the monitoring algorithms in this project will be based on degradation studies of Nel's next generation PEM electrolysers, the technique can be recalibrated and implemented on alkaline systems. The outcome of H2PANACA thus has the potential to open major new market opportunities for Nel both in Norway and abroad.