If you are a manufacturer dealing with high warranty costs and short equipment life — this project developed predictive health models and durable stacks that can reduce the average cost of ownership by 40% for AEL and PEMEL technologies.
Extending Green Hydrogen Electrolyzer Lifespans to Lower Total Cost of Ownership
Imagine if your car's engine wore out faster every time you stopped and started it in traffic. This project studies why hydrogen machines break down when powered by unpredictable wind or solar energy. By creating a digital health monitor and better materials, they make these machines last much longer and cost less to run.
What needed solving
Green hydrogen electrolyzers are currently too expensive and wear out too quickly, especially when powered by fluctuating renewable energy. This leads to high operational costs and frequent, expensive equipment replacement.
What was built
The project is building predictive state-of-health diagnostic tools, durable electrolyzer stacks with reduced critical materials, and a dedicated online data center for harmonized testing protocols.
Who needs this
Who can put this to work
If you are an operator dealing with unstable power feeds that damage your hydrogen equipment — this project developed control strategies and dynamic modeling to handle RES electrical profiles, extending the useful life of the system.
If you are a plant manager dealing with the high cost of critical raw materials in hydrogen systems — this project developed high-performance technologies with minimal CRM content to enable easier scalability and recyclability.
Quick answers
How does this affect the cost of owning an electrolyzer?
The project expects to reduce the average cost of ownership by 40% for AEL and PEMEL technologies, and by 70% for AEMEL and SOEL technologies.
Can this be scaled to industrial levels?
Yes, the project aims to reach 15% of European production capacity, which corresponds to approximately +3GW/a based on IEA 2022 data.
What is the IP or licensing potential?
Based on available project data, the project develops predictive control systems, new operating strategies, and durable stack components that could be licensed to manufacturers.
How long is the testing period for the new stacks?
The project validates solutions in short stacks for at least 10,000 hours or uses accelerated stress tests to extrapolate a minimum of 40,000 hours.
How is the technology integrated with renewable energy?
It uses dynamic modeling and simulation to evaluate the impact of RES electrical profiles on durability and develops control strategies to diminish degradation during transient operations.
Who built it
The consortium is heavily industry-driven with a 59% industry ratio, comprising 10 industrial partners including 6 SMEs. This strong commercial presence, combined with 5 universities and 2 research institutes across 9 European countries, indicates a high focus on translating technical degradation models into marketable industrial products.
Contact Politecnico di Torino regarding the development of lifetime prediction models.
Talk to the team behind this work.
Contact us to identify the specific industrial partners in the ELECTROLIFE consortium for licensing opportunities.