Low-Cost Manufacturing of High Temperature Electrolysis Stacks

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’ FlexCellTM

  • 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 FlexCellTM support and membrane layers to increase active cell area

Nexceris’ FlexStackTM

  • 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.