Developing an efficient and durable electrolyzer stack involves overcoming four critical challenges:
Efficiency
Maximizing energy conversion efficiency from electricity to hydrogen is vital. Our stack designs integrate advanced materials and component designs to achieve an industry-leading electrical efficiency.
Durability
Ensuring the stack's longevity is a complex task, as customers expect lifespans of 40,000 to 80,000 hours - far exceeding traditional fuel cell requirements. We conduct Accelerated Stress Tests (AST) and develop degradation models to predict and enhance stack lifetime under various operating conditions.
Cost
Balancing advanced technology with cost-effectiveness remains a persistent challenge. By leveraging innovative designs and materials, we aim to deliver competitive solutions that meet both, technical and cost targets.
Hydrogen Pressure
Operating at 30+ bar differential pressure directly at the stack level reduces the need for mechanical compression, thus enhancing system efficiency and lowering costs.
With AVL, customers gain access to a full package of engineering and design services for PEM electrolyzer stacks, complemented by a global supplier base for stack materials and system integration. From initial concept to series-production readiness, we deliver tailored solutions that meet customer-specific requirements. Our offering includes:
- End-to-End Stack Development: From component materials to complete stack designs, from engineering to experimental validation, from concept to start-of-production.
- Proven PEM electrolyzer stack reference design: Utilizing AVL’s in-house stack design as starting point for commercial stack development projects
- Validation and Testing: Our global test centers are equipped with state-of-the-art test systems and proven testing methodologies (DVP) to validate and verify your PEM electrolyzer stack, and to guide you to a series-production release with confidence.
Stack Design and Optimization
Our experience in stack development includes completely custom-designed stacks as well as optimizing or troubleshooting existing stack designs. Cutting-edge models and simulation tools are an important element in achieving this.
Design Verification
We define Design Verification Plans (DVPs) based on our deep understanding of fuel cell and electrolyzer technology, and the failure modes and effects associated with these technologies. We execute testing service with our in-house electrolyzer testbeds.
System Optimization Support
In addition to designing complete systems, we excel in refining and enhancing existing systems. Whether it’s improving efficiency, extending lifespan, or addressing specific performance challenges, we deliver failure analysis, consulting, and engineering solutions.
Operating Strategy
Every stack design requires a well-balanced operating strategy to assure efficient operation, while making sure that the stack meets lifetime targets. Our stack/system interface team has the expertise and the experience to define the operating strategy your stack needs.
Material Characterization
We specialize in material characterization for electrolyzer stacks, providing critical insights for stack design and performance optimization. Our expertise spans beginning of life and degraded material analysis at macro and micro levels, supporting simulations, failure analysis, and benchmarking. Equipped with advanced tools and expert engineers, we drive durable, high-performance, cost-effective stack solutions.
Related Topics
We are constantly working on new solutions. The following might be interesting for you:
Test stations for PEM and Alkaline electrolyzers
Fuel cells and electrolyzers are excellent solutions for efficiently achieving a CO2-neutral future. Especially since their application is multifaceted. It ranges from vehicles of all sizes to energy generation and storage to the starting point for synthetic fuels (e-fuels). Develop and optimize targeted fuel cell systems by using our simulation.