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Austin Power Engineering LLC1 Cameron St
Wellesley, MA 02482USA
www.AUSTINPOWERENG.comyang.yong@austinpowereng.com
© 2019 Austin Power Engineering LLC
1 GW Hydrogen Electrolyzer Plant Design and Cost Analysis
Yong Yang
President
November 7, 2019
1
Austin Power Engineering LLC is an independent technology consulting company that focuses mainly on bottom-up technical cost modeling.
Source: Dr. Rajesh Ahluwalia of ANL
HT/LT Radiators
Demister
Electric Motor
PEFC
Stack
AirExhaust
Humidified Air
HT Coolant
Enthalpy
Wheel
LT Coolant
Purge Valve
Recirculation Pump
LT Coolant Pump
HT Coolant Pump
Fan
Ejector
Pressure RegulatorMembrane
Humidifier
Dilution Mixer
Air Filtration
Hydrogen
Tank
Air Bypass
HT/LT Radiators
Demister
Electric Motor
PEFC
Stack
AirExhaust
Humidified Air
HT Coolant
Enthalpy
Wheel
LT Coolant
Purge Valve
Recirculation Pump
LT Coolant Pump
HT Coolant Pump
Fan
Ejector
Pressure RegulatorMembrane
Humidifier
Dilution Mixer
Air Filtration
Hydrogen
Tank
Air Bypass
Demister
Electric Motor
PEFC
Stack
AirExhaust
Humidified Air
HT Coolant
Enthalpy
Wheel
LT Coolant
Purge Valve
Recirculation Pump
LT Coolant Pump
HT Coolant Pump
Fan
Ejector
Pressure RegulatorMembrane
Humidifier
Dilution Mixer
Air Filtration
Hydrogen
Tank
Hydrogen
Tank
Air Bypass
Cathode pinTop cover
Insulator case
Spring plate
Anode can
Anode
Cathode
Separator
Cathode lead
Safety vent
Gasket
Insulator
Terminal plate
CID
2019 YY
Hydrogen
Electrolysis
Hydrogen
Storage
Fuel Cell Battery
2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
Hydrogen & Fuel Cell Manufacturing Cost Modeling
2014 2015 2016 2017 2018 2019
Arthur D Little / TIAX Austin Power Engineering
Introduction Overview
2
We will analyze a 1 GW (200,000 Nm3/hr / 500 ton H2 per day) hydrogen electrolysis plant capex.
2019 YY
Project Objective
Total Project CostStack + BOP
Factory CostOEM MarkupX= Additional Project
Cost+
Electrolysis Plant CAPEX
Directlabor
DirectMaterials
FactoryExpense
General
Expense
Sales
Expense
Profit
Sale Price / Capex
Fixed Costs
• Equipment and Plant Depreciation
• Tooling Amortization
• Equipment Maintenance
• Utilities
• Indirect Labor
• Cost of capital
• Overhead Labor
• Building
Variable Costs
• Manufactured Materials
• Purchased Materials
• Fabrication Labor
• Assembly Labor
• Indirect Materials
Corporate Expenses
• Research and Development
• Sales and Marketing
• General & Administration
• Warranty
• Taxes
Factory Cost
* Have done 200 kW, 1MW, 2 MW, 10
MW, 50 MW, 100 MW, 250 MW, 500 MW
hydrogen electrolysis plant cost analysis
for various clients.
3
Approach Manufacturing Cost Modeling Methodology
This approach has been used successfully for estimating the cost of various technologies for commercial clients and the DOE.
Technology
Assessment
Manufacturing
Cost Model
Scenario
Analyses
Verification &
Validation
• Literature research• Definition of system and component diagrams• Size components• Develop bill-of-materials (BOM)
• Define system value chain• Quote off-shelve parts and materials• Select materials• Develop processes• Assembly bottom-up cost model •Develop baseline costs
• Technology scenarios• Sensitivity analysis • Economies of Scale• Supply chain & manufacturing system optimization• Life cycle cost analysis
• Cost model internal verification reviews• Discussion with technical developers• Presentations to project and industrial partners• Audition by independent reviewers
Membrane
8.0%
Stack
Conditioning
2.7%
Seal
8.4%
Balance of Stack
2.4%
Bipolar Plate
26.1%
GDL
5.1%
Electrode
41.0%
Stack Assembly
6.3%
2019 YY
Anode Ink
Anode Side
Catalyst Layer
Membrane
Processes
Cathode Side
Catalyst Layer
Cathode Ink
Hot Press
Lamination
Purchased GDL
Purchased GDL
Pt
Pt
Nafion®
Ionomer
99.9% 98.5%
99.9% 98.5%
99% 98.5%
100% 98.5%99% 98.5%
99% 98.5%
100% 100%
100% 100%
100% 100%
100% 100%
100% 100%
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO
To
tal
Co
st
of
Ow
ers
hip
($
)
PEMFC Plug Hybrid Vehicle
Full Battery Electric Vehicle
4
Combining performance and cost model will easily generate cost results, even when varying the design inputs.
2019 YY
Process Simulation
Energy requirements
Equipment size/ specs
Product Costs
Product cost (capital,
O&M, etc.)
Conceptual Design
System layout and
equipment requirements
Capital Cost EstimatesSite Plans
Safety equipment, site
prep, land costs
High and low volume
equipment costs
Air (POX only)
Nat. Gas
Water
Fuel
Reformer PSA
H2-rich gas
H2-poor gas
Catalytic
Burner
HeatCold
Water
99.99% pure H2
Low
Pressure
Storage
Medium
Pressure
Storage
High
Pressure
Storage
Flow
cntrlr
Flow
cntrlrFlow
cntrlr
Dispenser
To Vehicle
CO2
H2O
Compressor with intercoolers
Cooling
Tower
Process cost
Material cost
Tape Cast
Anode
Powder Prep
Vacuum
Plasma
Spray
Electrolyte
Small Powder
Prep
Screen
Cathode
Small Powder
Prep
Sinter in Air
1400CSinter in Air
Forming
of
Interconnect
Shear
Interconnect
Vacuum
Plasma
Spray
Slurry
Spray
Screen
Slurry Spray
Slip Cast
Finish Edges
Note: Alternative production processes appear in gray to the
bottom of actual production processes assumed
Braze
Paint Braze
onto
Interconnect
Blanking /
Slicing
QC Leak
Check
Interconnect
Fabrication
Electrolyte CathodeAnode
Stack Assembly
Fuel Station Perimeter
Electrolyzer or SMR,
High-Pressure
Compressor
H2 High Pressure
Cascade Storage
System
Gaseous Fuel
Dispensing Islands
Underground Piping with shared conduit
Vent
Building
Covered Fueling Island
CNG High Pressure
Cascade Storage System
Fire Detector
Walls with minimum fire rating of 2 hours
Wall openings (doors & windows)
Building intake vents
Adjoining property that can be built on
Public sidewalks, parked vehicles
Streets
Railroad tracks
Other flammable gas storage
5 ft
25 ft
50 ft
10 ft
15 ft
10 ft
15 ft
10 ft
Minimum set-back distances for hydrogen and/or natural gas
storage (more stringent gas noted if relevant)
Property of:
TIAX LLC
1061 De Anza Blvd.
Cupertino, CA 95014
Task 5 CNG/Hydrogen Fueling
Site Plan - Fueling Station
Hydrogen and CNG fueling station
SIZE DWG BY DWG NO REV
A Stefan Unnasch B0228 - S0022 1
SCALE 1" = 8 ft 5 Jan 2004 SHEET 1 OF 110 ft
Security FenceNG line in
ft
ft
ft
ft
ft
ft
ft
ft
Process Cost Calcs
Material
Process
$0
$1
$2
$3
$4
$5
$6
$7
$8
$9
$10
Lapp
ing
CM
P
Wet
ther
mal O
xida
tion
Spin
Coa
ting
Wet
Etching
SiO
2
DC S
putte
ring
Ni
RF S
putte
ring
E
Spin
Coa
ting
Stepp
er
DC S
putte
ring
Ag
Stripp
ing
Spin
Coa
ting
Stepp
er
Dry
Etchi
ng S
iO2
DRIE
Si
Wet
Etching
SiO
2
Dry
Etchi
ng N
I
Wafe
r C
ost
($)
Approach Manufacturing Cost Modeling Methodology
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
3-Year TCO 5-Year TCO 10-Year TCO 15-Year TCO
To
tal
Co
st
of
Ow
ers
hip
($
)
PEMFC Plug Hybrid Vehicle
Full Battery Electric Vehicle
5
1 GW hydrogen electrolyzer plant boundary limits:
2019 YY
Electrolyzer stack
Balance of plant
AC-DC power supply
System control
Feed water treatment
Gas / liquid loops
Compressor (if needed)
De-oxygen unit
Gas drying
Cooling system
Piping, fitting, valves,
instrument
Assembly, conditioning,
testing, packaging
Hydrogen Output
30 barg
Oxygen limit: <5 ppm
Moisture content:
-65 oC dew point
Grid connection
Optional additional hydrogen
compression
Optional hydrogen storage
Peripheral components
Project development
Permitting
Engineering
Civil works and installation
Land use
Selling, general and
administrative expenses,
margins
Capex
Included in analysis Highly site and situation-specificIndicative estimated for engineering and
project cost is given separately based on
textbook factors
Approach Project Scope
Approach Cost Reduction Options
62019 YY
Comparing large scale hydrogen electrolysis plant with small hydrogen electrolyzer, cost reduction mainly comes from the following areas:
1. Improve stack performance
• Increase current density
• Simplify stack structure
• Reduce precious metal loading
2. Large scale production
• Process automation, etc.
3. Increase the stack size
• Current 1~5 MW
• Future 5~20 MW
4. System BOP optimization
• Power supply
• Mechanical compressors if apply
• H2 gas purification
5. Low cost region manufacturing
Modular vs Integrated
• Capex
• Project cost
• O&M cost
Approach Stack Options
72019 YY
We screened major electrolyzer manufacturer’s MW level electrolyzer stacks.
Alkaline
electrolyzer
PEM
electrolyzer
Hight temperature
electrolyzer
Atm. pressure Pressurized Atm. pressure Pressurized SOEC
Proton
Conductive
SOEC
Commercial
Pre-commercial
• NEL A485 2.3 MW • McPhy 2 MW Module
• Chinese Manufacturers
- Peric
- Jingli
- Tianjin Continental
• NEL/GHW• ThyssenKrupp
• Asaki Kasei
• Siemens
• Hydrogenics 3MW
• ITM Power 2MW Module
• NEL/Proton Onsite MW
Module
• Giner EXL 1MW
• Siemens 1~2 MW
• >Potential 10 MW stacks
• Tubular
• Planar
The chosen cell voltages and current densities are based on current technology status.
8
• The chosen cell voltage (1.75V) largely determines the cell efficiency (85% HHV)
• This low cell voltage is used to reflect that such large plants will be optimized for efficiency.
• Assume current atm. pressure alkaline electrolyzer current density is 175 mA/cm2
• Assume current PEM electrolyzer current density is 1,500 mA/cm2.
2019 YY
Approach Stack Options
Current Technology
Future Technology
Approach BOP Options
92019 YY
We must consider the capex, project cost, as well as O&M cost when we design the electrolysis plant project.
BOPModular
Design
Integrated
Design
Capex $$$ $$
Project Cost $ $$$
O&M Cost $$$ $$
Outdoor Modular Design Integrated BOP Design
10
Major stack specifications summary:
2019 YY
Design Scenarios 1 GW Hydrogen Electrolysis Plant Stack
Parameter
Alkaline
Electrolyzer
Current KPI
Alkaline
Electrolyzer
Future KPI
PEM
Electrolyzer
Current KPI
PEM
Electrolyzer
Future KPI
Plant size (MW, DC basis) 957 960 960 960
Stack size (MW) 2.3 10 2.5 10
# of stacks 416 96 384 96
Cell voltage (V) 1.75 1.75 1.75 1.75
Current density (A/cm2) 0.175 0.75 1.50 2.50
# of cells 258 258 258 258
Stack voltage (VDC) 452 452 452 452
Stack Current (A) 5,088 22,124 5,531 22,124
Cell active area (cm2) 29,077 29,499 3,687 8,850
Actual cell area (cm2) 34,208 34,704 4,852 11,644
Operating Pressure (barg) 0.02 .06 30 30
Stack production volume (GW/year) 1 1 1 1
Purity (%) 99.99 99.99 99.99 99.99
Oxygen limit <5 ppm <5 ppm <5 ppm <5 ppm
Moisture content - 65 °C dew point - 65 °C dew point - 65 °C dew point - 65 °C dew point
11
Major BOP components summary:
2019 YY
Design Scenarios 1 GW Hydrogen Electrolysis Plant BOP
Parameter
Alkaline
Electrolyzer
Current KPI
Alkaline
Electrolyzer
Future KPI
PEM
Electrolyzer
Current KPI
PEM
Electrolyzer
Future KPI
Power supply x x x x
H2 gas/liquid separator x x x x
O2 gas/liquid separator x x x x
H2 gas lye scrubber x x
H2 booster compressor x x
De-oxo unit x x x x
TSA dryer x x x x
DI water system x x x x
Stack cooling system x x x x
H2 gas chiller before boost compressor Included in the boost
compressor cost
Included in the boost
compressor cost
Included in the boost
compressor cost
Included in the boost
compressor cost
H2 gas chiller before TSA dryer Included in the deoxo
unit cost
Included in the deoxo
unit cost
Included in the deoxo
unit cost
Included in the deoxo
unit cost
# set of BOPs in system 2 2 2 2
Current Alkaline: 1 GW Alkaline (2.3 MW stack), 2 sets of BOP, simplified P&ID
12
O2 VentPTTC
FACILITY INTERFACE
Vents to atmosphere outside facility
Tap Water
H2 Vent
H2 Port
Non Return Valve
Solenoid Valve
TC
DI Water Treatment
PT TC
Solenoid Valve
Manual Valve
Check Valve
Pressure Release Valve
Process Filter
Ad
sorp
tion
Regen
eratio
n
TSADryer
Compressor
Electronic
Level SensorL
PT TC
Pressure Relieve Valve
Piston Pump
PTPressure Transducer
TCPressure Transducer
LEGEND
P Pressure Gauge
P
3-Way Manual Ball Valve
T1
Gas/Liquid Separator
DrainVessel
H1
L
x
TC
PTTCPT2
Gas/Liquid Separator
H2
L
xTC
To Lye Tank
PTTCPDry Cooling / Cooling Tower(Lye Cooling)
InstrumentAir
Nitrogen
De-oxoUnit
Cooling Water Outlet
Cooling Water Inlet
TCT3
Lye Scrubber
H2
L
x
TC
To Lye Tank
Lye Tank
Water Filtration
24 VDC Power
Supply
Power 110 VAC
Power 380VACControl System
230 kV 3 Phase
Auxiliary Power
Rectifier 452VDC;
Rectifier Transformer x 2866KV AC
……
Group 1
Group 25
Group 26
Power Transformer230KV AC / 66kV AC
…… 16 stacks
…… 16 stacks
…… 16 stacks
P
Cooling Water Inlet
Cooling Water Outlet
HydrogenCompressor
H2 BufferTank
Set # I BOP for stack group 1-13
Set # 2 BOP for stack group 14-26
Circulation Pump
Manual Valve
Circulation Pump
2019 YY
13
Current Alkaline 1 GW Plant Layout
2019 YY
450 meter
100meter
42meter
150 meter
40 meter
230KVSubstation
Indoor
Indoor
10 meter
20 meter
Alkaline 2.3MW x 416Total area: 172 m x 450 m =77,400m2
Indoor area: 48,880 m2
60 x 30 meter
Indoor
System Control& Offices
Gas/ liquid separationKOH Scrubber De-oxo TSA Dryer
4 meter
7 m
eter
DI Water
20 meter
10 meter
KOH Scrubber De-oxo TSA DryerGas/ liquid separation
20 meter
10 meter
Compressor
14
Atmospheric pressure alkaline electrolyzer design:
Key Parameters
Diaphragm
• Zirfon Perl ® diaphragm
• 0.5 mm thickness
Anode Electrode
• Substrate: 0.3 mm Ni Mesh
• Coating: NiAl (56/44)wt; 90 µm
Cathode Electrode
• Substrate: 0.3 mm Ni Mesh
Frame / Structure Ring
• Machined Carbon steel with PTFE
coating
Cell gasket
• EPDM
• 1 mm thickness
Separator Plate
• Ni coated carbon steel
• 2 mm thickness
US patent: 9,556,529
Current Alkaline: Stack Overview
2019 YY
15
Anode, cathode, and bipolar plate fabrication processes:
2019 YY
Current Alkaline Electrode and Bipolar Plate Current Process Assumptions
Sand
Blasting
SS Mesh Sheet
HCl
Etching
Vacuum
Plasma
Spraying
Anode:
Separator Plate Laser Cutting
Cathode:
Ni Mesh Sheet
Assembly Inspection
NiAl
Laser
Cutting
Press
Stamping
MachiningNickel
Coating
Laser CuttingPress
Stamping
Carbon Steel
16
Diaphragm and cell frame fabrication processes:
2019 YY
Welding
Carbon Steel
Turning Milling
Frame:
Gas/liquid Separator Chamber
Membrane Support Ring
Carbon Steel
Membrane
Assembly
Inspection
Plasma
Cutting
Bending
(round)
Laser CuttingNickel
Coating
PTFE
Coating
Membrane O-ring
Membrane
PPS Felt
Water Jet
Cutting
Plasma
Cutting I Welding Machining
Carbon Steel
Nickel
Coating
Plasma
Cutting II
Frame
Assembly
Current Alkaline Cell Frame and Membrane Diaphragm
We designed the stacks based on patents and public available information, etc.
17
Future Alkaline Scenario:
10 MW Atm. Pressure Alkaline Electrolyzer Stack
2019 YY
Other Stack Scenarios Overview
Anode
Diaphragm
Cathode
Cathode Side Elastic Layer
Cathode Side Current Distribution Layer
Cathode Side Cell Shell
Cell Gaskets
Cell Pitch 6mm US patent: US 9,556,529
Single Element Cell
Anode Side Cell Shell
Anode Side Current Distribution Layer
Current PEM Scenario:
2.5 MW 30 Barg PEM Electrolyzer Stack
Anode
Membrane
Cathode
Cell Bipolar plate
Cell frame Frame
Gasket
Repeat cell components
MEA gasket
MEA gasket
PTL
PTL
Anode side
Cathode side
Cell frame
Frame seal
Frame seal
H2
O2
Sintered Ti foam
Sintered Ti foam
Formed Ti Plate
Formed Ti Plate
Cell frame
Frame seal
Frame seal
Future PEM Scenario:
10 MW 30 Barg PEM Electrolyzer Stack
Anode
Membrane
Cathode
Cell Bipolar plate
Cell frame Frame
Seal
US patent: US20170088959A1
Repeated cell components:
MEA gasket
MEA gasket
PTL
O2, Anode side
H2, Cathode side
Cell frame
Sintered Ti
foam
Sintered Ti
foamTi wire mesh
Ti wire mesh
Ti wire mesh
Ti wire mesh
PTL
Frame seal
Cell frame
Frame seal
Carbon
Paper
Carbon Paper
We assume there are two sets of BOP systems which make the system easy to maintain and give the benefit of resiliency.
18
Example Power Supply Diagram
2019 YY
Example De-oxygen & TSA Dryer Diagram
BOP Components
Major BOP
ComponentsDescriptions
Power supply 230KV Substation; N+1 transformer
design
H2 gas/liquid separator Integrated
O2 gas/liquid separator Integrated
H2 gas lye scrubber Integrated
H2 booster compressor ~20,000 HP x 2
De-oxo unit Pt on Al2O3 pellets at 108 Co
TSA dryer UOP Molesieve pellets
DI water system Electric conductivity, <1 Siemens/cm for
PEM; <5 Siemens/cm for Alkaline
Stack cooling system ~20,000 cooling tons
0
500
1000
1500
2000
2500
3000
Today 1~2 MW Electrolyzer Capex 1 GW electrolyzer Plant Capex
Elec
tro
lyze
r C
apex
($/k
W)
19
• Today 1~2 MW electrolyzers’ capex ranges from $600/kW to $2,000/kW
• Modelled 1 GW electrolyzers’ capex ranges from $400/kW to $600/kW1
Estimated 1 GW electrolyzer plant capex fall into the range of between $400/kW and $600/kW.
2019 YY
Capex Summary
2
1. Made in US or western Europe countries; cell efficiency is about 85%; output H2 gas purity is 99.99% at 30 barg
2. Units made in China and sold in China only; as low as $200~300/KW
0
500
1000
1500
2000
2500
3000
Today 1~2 MW Electrolyzer Total Project Cost 1 GW electrolyzer Plant Total Project Cost
Tota
l Pro
ject
Co
st (
$/k
W)
Total project cost also includes project “soft” cost which is highly site and situation specific.
20
• Typical Project “Soft”
Cost
• Permitting
• Building (including
service facilities)
• Engineering &
supervision
• Installation
• Legal expense
• Contract fee
• Contingency
2019 YY
Total Project Cost Discussion
• Container based 1~2 MW electrolyzers’ project cost is minimum
• 1 GW electrolyzer plant total project cost ranges from $600/kW to $1,800/kW
(additional 50%~200% project “soft” cost)
*
* Units made in China and sold in China only; as low as $200~300/KW
21
Thank You!
Contact: Yong Yang
Austin Power Engineering LLC
1 Cameron St,Wellesley, MA 02482
+1 781-239-9988+1 401-829-9239
yang.yong@austinpowereng.comwww.austinpowereng.com
Online research report store: http://austinpowereng.com/store.php
2019 YY
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