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Module size: Electrolysers of 20 MW and even 100 MW are now the norm. The balance of plant has now been optimised. There are dedicated suppliers for the electrical equipment, and this is no longer done by electrolyser manufacturers. This enables standardisation and the achievement of lower costs. Power supply is also optimised, with stack design considering variable load and efficiency. Use of pressurised electrolysers allows a reduction in compression needs. The combination of these effects unlocks a lower cost for the auxiliary equipment complementing the advances from R&D for the stack. Learning-by-doing: Leading manufacturers have built experience with project execution. Some typical business cases are starting to arise, which creates the opportunity to both standardise and optimise the design to satisfy requirements. International players and organisations serve as platforms to exchange lessons and work towards global standards. New manufacturing plants are constructed, which have a much lower cost than their predecessors. Engineering, construction, equipment suppliers, are all familiar with electrolysis, which enables faster project development, leaner execution and lower costs. R&D: Some of the largest cost tickets for electrolysers have been tackled before. Now, the focus shifts towards material optimisation. If electrolysers are to achieve large scale, the materials used need to decrease in quantity, not only to reduce cost, but also to ensure sustainability and having to increase current supply by several orders of magnitude. For alkaline technology, this means a transition to a platinum and cobaltfree design. This has already been achieved today by some manufacturers, but not all. Keeping these two materials in the design could limit the role that alkaline electrolysers have in the future. For PEM, a combination of reduction, higher hydrogen production and recycling strategies, allows reducing the iridium and platinum content by unit of installed capacity by 70% and 80% respectively. This is particularly important for iridium, which has currently limited market liquidity (i.e. high price volatility of a factor of 15 times between the minimum and maximum over the last 20 years), limited supply diversification (over 85% of the current supply comes from South Africa) and a relatively small market (current supply could only support a capacity of about 75 GW of electrolysis). Stage 3: A global market Manufacturing scale: Hydrogen use is growing across all sectors, from planes to ships to trucks and industry. This requires a larger electrolyser production upstream. This creates competition and attracts new players. What in the previous stage was only possible for a few companies, is now more widespread and accessible to multiple enterprises. This in turn creates competition to optimise manufacturing further and have an edge in what is now a market with tighter margins. This race benefits project developers further, since the lowest cost can be achieved. Module size: There are multiple choices available for project developers. From 100MW+ modules that are suitable for industrial applications to singledigit MW modules that, by this stage, also incorporate some of the benefits of larger modules. Higher current densities have been achieved for both alkaline and PEM electrolysers, which enables a smaller footprint for all the sizes. AEM and solid oxide have already crossed the boundary from lab to commercialisation and module sizes are in the multi-MW scale. Learning-by-doing: Deployment still leads to learning, but the largest cost reduction has been achieved by now. The cost starts being dominated by core materials, with an optimised stack and balance of plant. There is still potential for cost reductions in the next generation of electrolysers, AEM and solid oxide. SCALING UP ELECTROLYSERS TO MEET THE 1.5°C CLIMATE GOAL 89PDF Image | GREEN HYDROGEN SCALING UP ELECTROLYSERS
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