// ZSW electrolysis stack technology

Proven and patented stack designs

  • Active cell areas from 100 to 3,000 cm²
  • Pressure range atm. up to 30 bar
  • Maximum power in pressurised version: 500 kWel
  • 2 MW stack 30 bar in development

Product-related stack development

  • Technology readiness level (TRL) 5-6 (breadboard validation or prototype demonstration in relevant operational environment)
  • Full documentation of all components
  • Preliminary design approval and certification in accordance with Pressure Equipment Directive/ AD 2000

Patented components ready for series production

  • Cell frames 100 to 3,000 cm² validated and ready to go into production, 10,000 cm² in development
  • Electrode packages in flexible and rigid designs
  • Use of EPDM or plastic cell frames capable of injection moulding
  • Specific energy consumption suitable for adaptation with various validated industrial coatings

Marketing by industry partners

  • Option of licensing components & stacks to industrial customers
  • Extensive range of test facilities for stacks/ components (ElyLab)
ZSW alkaline electrolysis stack technology in action, consisting of cell frame, electrode package and diaphragm. With an active cell area of around 3000 cm2, the stack is designed for an output of approx. 0.5 MW at 30 bar.
Stack prototypes are stacked by hand in the laboratory. Plans are already in place for a fully automated production line with an output of up to approx. 5 GW per year for this stack design (alkaline high-pressure electrolysis 30 bar, power class 0.5 MW).
Side view of an electrode package. The electrodes are fitted with spring-loaded current transformers for contact with the bipolar plate. The design patented by the ZSW allows a “zero-gap” configuration which enables higher levels of efficiency due to the reduced ohmic losses in the electrolysis cell.
Electrolysis stack (alkaline high-pressure electrolysis) with a connected load of approx. 300 kW. At a pressure level of 30 bar, this electrolyser can produce around 150 kg of hydrogen per day.
Electrode package for alkaline high-pressure electrolysis, consisting of bipolar plate, anode and cathode, each with an active cell area of approx. 3000 cm2 in this case.
Laboratory stack consisting of up to 20 single cells with a maximum operating pressure of 16 bar. The test environment is used to validate electrode designs and electrode coatings under real operating conditions. Single cell voltage taps allow parallel testing of different cell configurations.
Electrode in the form of a perforated sheet coated with Raney nickel with an active cell area of approx. 3000 cm2.
Design modifications to the stack and components can be examined on screen using suitable CAD models before proceeding with adaptations.
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The ZSW Technical Center develops application-oriented technology modules for the production of hydrogen and synthetic downstream products, which are implemented and tested on a technical scale. 

 

Contact 
ElyLab test center: 

Thomas Ottitsch
Email: thomas.ottitsch(at)zsw-bw.de
Phone: +49 711 7870 362

 

Contact 
Electrolysis research:

Tonja Marquard-Möllenstedt
Email: tonja.marquard-moellenstedt(at)zsw-bw.de
Phone: +49 711 7870 285