Novel PEM electrolyzer catalyst-coated membrane for more efficient and lower-cost green hydrogen production

 

 

Today, in pursuit of sustainable energy solutions, Proton Exchange Membrane (Proton Exchange Membrane) PEM technology has a wide range of applications in hydrogen production, energy storage, energy conversion and other sustainable energy fields.

 

A complete PEM electrolyzer mainly includes the following key links:

Catalyst-coated membrane (CCM): This is the heart of the system, responsible for the electrochemical reaction.

The electrolyzer structure, bipolar plate flow field, and diffusion layer thickness design are the structures that support the CCM and provide current channels.

 

Why do you need customization?

Catalyst Coated Membranes (CCM) Catalyst Coated Membranes

Different application scenarios have different performance requirements

Through customization, the CCM material (proton exchange membrane) thickness and noble metal loading can be optimized for specific applications to improve system efficiency.

 

Advantages of our customized CCM

In large-scale hydrogen production applications, CCM needs to have a high degree of stability and long life. By customizing CCM, we can precisely regulate the type of catalyst, coating thickness and coating method to achieve the best performance. We focus on CCM cutting-edge technology to manufacture high-performance proton exchange membrane electrode Apter Power's catalyst coating membrane

( CCM) is the core component of its PEM electrolyzer. CCM is composed of catalyst, membrane and diffusion layer. It is responsible for the catalytic reaction and current conduction of the electrolyzer.

 

Apter Power PEM Electrolyzer membrane electrodes can be customized according to user needs to meet different application scenarios.

The following are Apter Power PEM Electrolyzer membrane electrode customization instructions and requirements:

Power density: The power density of the membrane electrode can be from 2A/cm2 to 3A/cm2

Corrosion resistance: The membrane electrode needs to have good corrosion resistance.

Cost: The cost of membrane electrodes can also be optimized according to user needs (choose proton exchange membranes from different manufacturers). We

are committed to providing customers with large-scale electrolyzer membrane electrodes that meet their needs, and continue to carry out technological innovation to improve the performance of membrane electrodes. and cost-effective.

 

Apter Power's new CCM spray method has significant advantages:

our multi-layer structure increases the contact area between the catalyst and reactants, thereby increasing the activity of the catalyst, with high power density, high efficiency and high durability. In addition, the new CCM can Protects the catalyst from corrosion in the electrolyte, thereby improving the stability of the catalyst.

The new nanostructured CCM spraying method can use less catalyst loading, thereby reducing manufacturing costs, improving reaction efficiency, increasing the strength of the electrode, and can withstand higher pressure and stress.

Catalyst sauce consists of catalyst, solvent and other additives. The catalyst is usually platinum or iridium, and the solvent is usually chemical water or alcohol. The spraying method can evenly coat the catalyst on the membrane, which can conduct current more effectively. The catalyst

's activity, improving the performance of the electrolyzer.

Current density is one of the important performance indicators of an electrolyzer. It indicates the amount of current that the electrolyzer can output per unit area. The higher the current density, the greater the power output of the electrolyzer, thereby reducing the power cost of the electrolyzer.

 

Apter Power's PEM electrolyzer adopts an advanced Membrane Electrode Assembly (MEA) design and has the following advantages:

High performance: Apter Power's MEA uses advanced catalysts, membranes and electrode materials to improve the performance of the electrolyzer. Apter Power's MEA Features high power density, high efficiency and high durability.

High reliability: Apter Power's MEA adopts a high-reliability design to ensure that the electrolyzer operates normally in harsh environments and has good reliability.

Advanced Catalyst: MEA adopts nanotechnology (catalyst), which can improve the activity and stability of the catalyst.

High Efficiency Membrane: MEA adopts high efficiency membrane, which can improve the conductivity and corrosion resistance, and improve the efficiency of the electrolyzer.

 

Apter Power Membrane Electrode Encapsulation Hot Pressing Process

This process mainly includes the following steps:

Membrane electrode assembly (MEA) is placed in the encapsulation mold. The MEA consists of a catalyst-coated membrane, a gas diffusion layer, and a sealed frame.

Heat the encapsulation mold to a certain temperature.

Apply pressure to the encapsulation mold.

Cool the MEA encapsulation mold.

The hot pressing process can make the membrane electrode assembly tightly combined with the packaging mold to form a complete membrane electrode. This process can also firmly fix the gas diffusion layer and the sealing frame in the membrane electrode assembly to prevent gas leakage.

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The membrane electrode packaging process has the following advantages:

Flow channel cutting: use high-precision cutting equipment to ensure that the size and shape of the CCM meet customer design requirements.

The membrane electrode assembly can be closely combined with the packaging mold, and the sealing performance of the membrane electrode can be improved.

It can firmly fix the gas diffusion layer and the sealing frame in the membrane electrode assembly to prevent gas leakage, improve the durability of the membrane electrode, and withstand the pressure of the electrolytic stack assembly, as well as the differential pressure operation of hydrogen and oxygen, the membrane electrode The packaging process is the key to the performance and reliability of the electrolyzer.

 

Apter Power Porous Transport Layer (PTL) 

porous structure: PTL adopts a porous structure to improve gas transmission efficiency. The size and porosity of the porous structure are optimized to ensure fast and uniform gas transport in the PTL.

High strength: PTL has high strength and can withstand the pressure and stress generated during the operation of the electrolyzer. PTL utilizes high quality materials and workmanship for strength and durability.

Corrosion resistance: PTL is corrosion resistant and can resist corrosion in the electrolyte. The PTL adopts corrosion-resistant materials, which can ensure the long-term stable operation of the PTL in the electrolyzer.

 

Apter Power's PTL design offers the following benefits:

Improved electrolyser performance: The porous structure of the PTL allows for more efficient gas transfer, thereby increasing the power density and efficiency of the electrolyser.

Reduced cost of electrolyzers: The porous structure of PTL can reduce the manufacturing cost of electrolyzers.

Extended cell life: PTL's high strength and corrosion resistance can extend cell life.

PTL design is an important part of Apter Power PEM electrolyzer technology, which can effectively improve the performance, cost and reliability of the electrolyzer.

 

The design pressure of MW PEM Electrolyzer is 20-30MPa.

The influence of design pressure:

Power density: Higher design pressure can increase the power density of the electrolyzer stack, because the power density of the electrolyzer stack is directly proportional to the pressure of the electrolyzer stack.

Corrosion risk: Higher design pressures increase the corrosion risk of the pot stack, as high pressure accelerates the corrosion of metals in the pot stack.

Lifetime: Higher design pressure will reduce the life of the pot stack because the metal in the pot stack will be subject to greater corrosion.

The Apter Power MW PEM Electrolyzer uses advanced design and manufacturing processes to reduce the risk of corrosion of the electrolyser stack, thereby increasing the life of the electrolyzer stack.

 

Apter Power MW PEM Electrolyzer has the following advantages:

High power density: The power density of Apter Power MW PEM Electrolyzer is as high as 2A/cm2 to 3A/cm2, which is the most advanced PEM electrolyzer on the market. High power density means that electrolyser stacks can take up less space, reducing installation costs.

 

Specific Description of Benefits:

High Efficiency: With an efficiency of up to 70%, our MW PEM Electrolyzer is the most efficient PEM electrolyser currently on the market. High efficiency means the electrolyser stack can produce more hydrogen, reducing operating costs.

Long life: MW PEM Electrolyzer adopts an advanced bipolar plate coating process, which can improve the corrosion resistance of the electrolyzer stack, thereby extending the life of the electrolyzer stack.

Scalability: Our MW PEM Electrolyzer is scalable and can be expanded according to demand. Scalability means that the electrolyser stack can meet the needs of different sizes.

High reliability: MW PEM electrolyser adopts a high-reliability design, which can ensure the normal operation of the electrolyzer in harsh environments. High-quality materials and processes have good reliability. Can meet the needs of various application scenarios.

 

Apter Power MW PEM Electrolyzer can be customized according to user needs to meet different application scenarios.

The following are customization instructions and requirements:

Power level: The power level of Apter Power MW PEM Electrolyzer ranges from 1 MW to 5MW, and modules can be added according to user needs.

Number of electrolyzers: The number of electrolyzers can be increased or reduced according to user needs to meet different hydrogen production needs.

Electrolyzer Type: Apter Power MW PEM Electrolyzer There are two types of electrolyzers, one is the traditional flat plate orientation electrolyzer and the other is the coiled circular electrolyzer.

Electrolyzer material: Apter Power MW PEM Electrolyzer electrolyzer is made of high-performance titanium alloy with high conductivity and corrosion resistance.

The following are the customization requirements for the MW PEM Electrolyzer:

Power level of the electrolyzer

Number of

electrolyzers Type of electrolyzer

Apter Power will provide customized solutions and quotations according to the needs of users.

Through customization, different needs of users can be met, and the application range and value of Apter Power MW PEM Electrolyzer can be improved.

 

PEM Electrolyzer Precautions:

* Overcurrent protection: Prevent the electrolyzer current from being too large, causing damage to the electrolyzer.

* Overvoltage protection: Prevent the electrolyzer voltage from being too high, causing damage to the electrolyzer.

* Temperature protection: Prevent the electrolytic tank temperature from being too high, causing damage to the electrolytic tank.

* Leakage protection: Prevent leakage in the electrolytic tank from causing electric shock to personnel.

The following matters need to be noted when using the Apter Power MW PEM Electrolyzer:

**The electrolyzer stack will generate a large amount of heat during operation and requires cooling. **If there is a problem with the cooling system, it will cause the electrolyzer stack to overheat, affecting the efficiency and life of the electrolysis reaction.

The PEM electrolyzer stack generates heat during operation and transfers the heat to the cooling water. The cooling water is cooled through the cooling tower or fan cooler. The cooled water is circulated back to the electrolyzer stack to cool the electrolyzer stack.

 

The following are specific instructions for precautions when using the MW PEM Electrolyzer:

MW-class PEM electrolyzer:

System thermal management: In large-scale PEM systems, thermal management is a complex but crucial issue, and poor thermal management can lead to reduced efficiency. , and may even cause system failure.

**Cooling system: Regularly check various components of the cooling system to make sure they are not damaged or blocked.

Make sure the cooling water flow and pressure meet the requirements, and clean the cooling system regularly.

**Safety: The electrolyzer stack should be installed in a well-ventilated place to avoid the leakage of hydrogen and oxygen generated by the electrolyzer stack. It is forbidden to use open flames or other fire sources near the electrolyzer stack. The electrolyzer stack should be equipped with corresponding safety protection measures. Such as fire alarm system, fire fighting system, etc.

**Maintenance: The electrolyzer stack should be maintained regularly to keep it running properly, and the maintenance work should be done by professionals.

By paying attention to the above points, the safe and reliable operation of the Apter Power MW PEM Electrolyzer can be ensured.

 

From customizing Catalyst Coated Membranes to designing and manufacturing MW-level PEM electrolyzers, each step involves highly professional and cutting-edge technology.

If you have customized requirements for PEM Membrane Electrode Assembly or related products, welcome to contact us. We have many years of experience and a professional technical team that can provide you with a full range of solutions.

> To learn more about cutting-edge information on proton exchange membranes and other sustainable energy technologies, please follow our WeChat public account.

> Professional manufacturing PEM Membrane Electrode Assembly team  

Let us work together to promote the sustainable development of the hydrogen economy!  

Thanks for reading!

Future-proof your business with green Hydrogen

The green Hydrogen produced by Apter Power electrolyzers is versatile, with applications in small and large industry, transportation, and power. We design modular hydrogen solutions that help your business maximize operational efficiency, energy security, cost reduction, and sustainability.

 

Achieve operational resilience and long-term business sustainability

The majority of today’s Hydrogen is produced with polluting natural gas. By switching from polluting gray or brown Hydrogen to emissions-free green Hydrogen, global industries can accelerate toward carbon-reduction goals.

 

Ammonia production

Steel and iron processing

Methanol production

Petroleum refining

Produced with 100% renewable energy, green Hydrogen can help your business decarbonize operations while ensuring reliable long-term Hydrogen supply.

 

Benefits of green Hydrogen:

Stabilize your Hydrogen supply

Decrease dependence on imported natural gas

Ensure continuity of service

Increase control over operational costs

Make progress toward carbon reduction targets

 

Decarbonize your fleet with sustainable, emissions-free fuel

The transportation sector is a significant contributor to global CO2 emissions. In the form of fuel by fuel cells or combustion engines, Hydrogen can be used as a sustainable alternative to gasoline or diesel. Green Hydrogen - produced by 100% renewable energy - is an emissions-free option for both large and small transportation applications.

 

Light duty passenger vehicles

Heavy duty vehicles such as trucks and buses

Maritime transportation

Aircrafts

Trains

Benefits of green Hydrogen:

Replace polluting fuels like diesel and gasoline with emissions-free Hydrogen

Benefit from longer range, faster refueling, and higher payload than EVs

Produce Hydrogen-derived synfuels such as green ammonia, and methanol

Reduce dependence on imported oil

 

Maximize energy reliability with increased flexibility

Because it can be stored for long periods and converted to electricity on demand, hydrogen is used as a form of reliable energy storage. The added flexibility and energy resilience that it provides can benefit a wide range of commercial to grid-sized customers.

 

Electric utilities

Critical infrastructure (hospitals, data centers, telecom towers, etc.)

‍Stored green hydrogen - produced by 100% renewable energy - helps utilities mitigate renewable energy intermittency and other grid reliability issues. Green Hydrogen provides critical backup power and creates a path to a more sustainable power grid.

‍

Benefits of green hydrogen:

Maximize renewable energy integration

Stabilize fluctuations in power generation and power consumption

Provide back-up power for grid disruptions

Increase flexibility

 

About Apter Power

Apter Power, a technological expert at the service of green hydrogen, develops cutting-edge technologies to design and produce PEM (Proton Exchange Membrane) electrolysers to meet new uses of hydrogen in mobility

our PEM electrolyzers ensure gas products of superior quality. It is easy to operate and requires low maintenance. Using a modular design strategy that splits the electrolysis system into skids, we are able to optimize costs, reduce installation costs, and make the electrolysis system transportable.

 

Benefits of green hydrogen

Green hydrogen is a versatile energy carrier that can be applied to decarbonize a wide range of sectors. It can be used directly or in the form of its derivatives like e-methanol, e-ammonia, or e-fuels to replace fossil fuels, coal or gas.

 

Only around 40% of global carbon dioxide (CO2) emissions originate from power generation which can be decarbonized via electrification. The other 60% of CO2 emissions originate from industry, mobility, buildings and others. These can be decarbonized via sector coupling, using green hydrogen and its derivatives to make renewable energy available to those sectors.

 

As the global demand for power increases, energy resources,

power grids and the environment face a variety of challenges

often resulting in high levels of pollution, greenhouse gas emissions and elevated indirect costs on society. There has been a shift to deploy renewable technology to meet diverse industry

demands- providing sustainable green energy.

 

Unlike traditional grid power, renewable energy is often unavailable or unpredictable, causing periods of supply and demand mismatch. In addition, costs of wind and solar are approaching grid parity, spurring further penetration of renewables onto an already aging infrastructure. This drives the need for high-capacity energy storage solutions.

 

Hydrogen generated using PEM electrolysis technology is key to fully leveraging renewable energy.

As an energy carrier, hydrogen provides daily to seasonal storage, creating a reliable source of dispatchable green energy for society’s current and future needs. With the response time of a battery and the storage capacity of pumped hydro, PEM electrolysis provides the interface to turn excess energy from variable wind and solar power into hydrogen, which can be converted back into electricity when needed or used as a high value chemical feedstock to support a variety of industrial applications.

 

Combining grid intelligence with renewable resources, hydrogen-based solutions

provide a dependable, environmentally conscious, low-cost energy supply to support:

• Power production

• Energy storage

• Power-to-gas

• Hydrogen fueling/mobility

• Grid and micro-grid balancing and load shifting 

 

For our electrolyzer system, we focus on PEM technology taking its name from the proton exchange membrane. The membrane’s special property is that it is permeable to protons but not to gases such as hydrogen or oxygen. As a result, in an electrolytic process the membrane takes on, among other things, the function of a separator that prevents the product gases from mixing. 

 

Global Service and Support Solutions

Apter Power is proud to offer products and services that assure a superior level of customer satisfaction. Our uncompromising attention to excellence and quality

 

 

Water Charging System

The raw water first enters the demineralized water preparation device, and after the process of ultrafiltration and secondary reverse osmosis, it then enters the lye tank, alkali distribution water tank and cooling device water tank.  The water in the lye tank and the alkali distribution tank will be prepared into lye, which will be sent to the air-liquid separator by the alkali distribution pump and enter the lye circulation system to supplement lye for the lye circulation system. The water in the water tank of the demineralized water cooler flows through the water-water heat exchanger under the output of the circulating water pump, and then enters the multiple coolers in the gas-liquid separator and hydrogen purification device, and finally returns to the water tank of the cooler.

 

Lye Circulation System

The electrolyte coming out of the electrolytic cell will enter two channels: One is rich in hydrogen, the other rich in oxygen. The electrolyte in both channels will enter respectively in  hydrogen separator and oxygen separator in the gas-liquid separation device where hydrogen and oxygen will be separated. After the separation, the lye in the two channels will meet, and after the process of alkali filter and lye cooler, it will enter the lye circulation pump, under whose pressure the lye will finally return to the electrolyzer, so as to realize the lye recycling in the hydrogen production system.

 

Electrolyzer

The lye from the lye circulation system enters the electrolytic cell, and the water begins to decompose under the action of direct current. Hydrogen and oxygen are produced respectively on the cathode plate and the anode plate of the electrolyzer. These hydrogen and oxygen along with the electrolyte flow from both ends of the electrolyzer into the gas-liquid separation unit.

 

Gas-liquid Separation Unit

Gas-liquid Separation Unit is equipped with hydrogen separation scrubber, oxygen separator, hydrogen cooler, gas-water separator, lye circulation pump and other equipment. The electrolyte containing hydrogen and oxygen pass through hydrogen separator and oxygen separator respectively, and the gas will be separated from electrolyte under the action of gravity. The separated oxygen will be discharged outdoors, while hydrogen will be further washed, cooled, separated and removed from droplets in the separator, and then enter the hydrogen purification unit.

 

Hydrogen Purification Dvice

Catalyzed by the catalyst, a chemical reaction between the hydrogen in the purification device and the residual oxygen in the hydrogen will happen as follow: 2H2+O2=2H2O

After cooling, adsorption and separation, the 99.999% high purity hydrogen will be available.

 

Hydrogen Storage Device

After the pressure is balanced by the hydrogen bus rack, the high purity hydrogen will be distributed to hydrogen storage tank.

 

Hydrogen Supply System

The main process of hydrogen supply system is as follows:

 

 

Hydrogen storage tank → Hydrogen bus → Hydrogen buffer tank → Hydrogen compressor → Hydrogen charging bus (or filling device) → Hydrogen tank group (or long tube trailer).

 

Auxiliary System

The auxiliary system for hydrogen production mainly includes: demineralized water preparation system, refrigeration and heat exchange system, compressed air supply system, lye storage system and nitrogen purging system. The description of each system is as follows:

 

Demineralized Water Preparation System

The demineralized water preparation system adopts conventional filtration, ultrafiltration and secondary reverse osmosis processes to meet the water quality requirement of hydrogen production system.

 

Process of Demineralization System:

Deep well water (with pressure) → disc filter → ultrafiltration device → ultrafiltration water tank → primary reverse osmosis high pressure pump → primary reverse osmosis device → secondary reverse osmosis high pressure pump → secondary reverse osmosis device → demineralized water tank → demineralized water pump → water points in hydrogen production system.

 

Refrigeration and Heat Exchange System

The equipment of refrigeration and heat exchange system  mainly includes buffer water tank, circulation pump, and compression refrigerator.

 

Compressed Air Supply System

The equipment of compressed air supply system mainly includes air compressor, filter, dryer and compressed air storage tank. This project is equipped with a set of instrument air supply device to meet air supply demand of the instrument of the whole hydrogen station. The equipment includes air compressor, air storage tank etc., to meet the gas requirement of instrument in hydrogen production system.