Research and Development Practices within PEM Water Electrolyzer Manufacturing to Support a Circular Economy
Authors: Carmo Marcelo , Motz Andrew R , Capuano Christopher B. , Dalton Luke T. , Ayers Katherine E. 
Published: August 2024

Nel Hydrogen has in the last decades substantially invested in R&D efforts to consolidate next-generation PEM stacks and systems towards a commercial pathway for these devices at scale. These innovative tasks have allowed the company to reach much lower values for levelized costs of hydrogen (LCOHs) supported by devices that are much more efficient and lower costs; but that still holds robustness and long-life characteristics. However, to truly represent a sustainable pathway, the production lifecycle needs to be considered, especially related to critical materials such as catalysts and polyfluorinated alkyl substances (PFAS) used for instance in the membranes. PFAS are beginning to be regulated globally, with a goal of for responsible manufacturing and hence zero disposal to the environment. Recycling programs for the polymers used in electrolyzers can assist in keeping them exempt from PFAS regulations, due to the minimized environmental impact and lack of related emissions. In addition, PEM electrolyzers use a significant amount of platinum group metals (PGMs), including iridium, one of the scarcest naturally occurring elements. Addressing these issues through recycling and a healthy circular economy of these key components is an important part of large-scale commercialization and deployment.

Recent customers have already raised questions about supplier philosophy and documentation of environmental practices. In other words, these large-scale market players are looking for instance to be ISO14001 certified; designed to minimize a company’s negative impact on the environment. While recycling of any chemicals is not specifically required by ISO14001, the standards include lifecycle assessments, integration of environmental aspects into product design, reduction of greenhouse gas emissions, and related topics where recycling would have positive impact on the metrics.

At the last 244th ECS meeting in Gothenburg 2023, we have shown how recycling (or PGM thrifting) is ultimately required to meet the IEA projected capacity demands for electrolyzers by 2050, or around 2500 GW globally. Our analysis has demonstrated that above 40% market share can be reached by 2050 for PEM electrolysis, proven that: 1)20% annual Iridium production (ca. 8 tons/year) is allocated for PEM electrolyzer manufacturing; 2) significant PGM thrifting (above 80%) is demonstrated for these devices; 3) life-time and robustness of these new low loading electrodes are maintained; and 4) a circular economy (responsible recycling) is stablished. Repurposing other components such as titanium, stainless steel, and fluoropolymers provides some additional value stream from reclamation as well. For maximum benefit, material collection methods need to be set up within the manufacturing facility, to capture waste materials and scrap, as well as through the field population, so that systems no longer being operated can be reclaimed for materials. This talk will cover some of the business considerations for effective recycling, as well as current practices.