BIL - MANUFACTURING INNOVATIONS FOR SCALING GREEN H2 TO FOSSIL-PARITY
PROJECT OBJECTIVES OVERVIEW THE GOAL OF THIS PROJECT IS TO DEVELOP AND PILOT AN ELECTROLYZER MANUFACTURING PROCESS [ON A RIGID SUBSTRATE THAT IS FULLY AUTOMATED, USING PLATE BY PLATE], STACK MANUFACTURING PROCESSES THAT ADVANCE THE CURRENT MANUFACTURING READINESS LEVEL (MRL) [4/5 TO AN MRL OF 8/9] BY THE END OF THE 3-YEAR PROJECT. ULTIMATELY, SCALING ELECTROLYZER MANUFACTURING VOLUME TO PRODUCE 100MW PROTON EXCHANGE MEMBRANE (PEM) ELECTROLYZER PLANTS WHILE REDUCING STACK COST ARE THE PROJECT’S PRIMARY OBJECTIVES. THE PROJECT WILL BE MANAGED IN THREE BUDGET PERIODS (BP) WITH THE FOLLOWING BP OBJECTIVES.
•BUDGET PERIOD 1 OBJECTIVES – INTEGRATION OF NEW MANUFACTURING TECHNIQUES AND FURTHER OPTIMIZATION OF INDIVIDUAL PROCESSES TO VALIDATE PRODUCTION CAPACITY AND CONSISTENCY, ESTABLISHING READINESS FOR INTEGRATION INTO THE COMPLETE MANUFACTURING SYSTEM. SELECTION OF [FULL CHARACTERIZATION TECHNIQUES AND FIDUCIALS] FOR SUBCOMPONENT [TRACKING]. ESTABLISHMENT OF [TESTING PROTOCOLS FOR SUBCOMPONENTS] AND [CORRELATION TO FULL-STACK] TESTING.
•BUDGET PERIOD 2 OBJECTIVES – INTEGRATION OF SUBCOMPONENT ASSEMBLY MANUFACTURING PROCESSES REDUCING [CYCLE TIME] FROM [350 MIN/PLATE (CURRENT) TO 90 MIN/PLATE/TOOL AND 13 MIN/PLATE VIA PARALLEL PROCESSING] WHILE REDUCING STACK COST TO [LESS THAN $270/KW].
•BUDGET PERIOD 3 OBJECTIVES – OPTIMIZE AN [AUTOMATED PLATE-BY-PLATE] MANUFACTURING PROCESS TO REDUCE [CYCLE TIME TO 7 MIN/PLATE], WHILE REDUCING STACK COST TO LESS THAN $100/KW AND ADVANCING THE CURRENT MANUFACTURING READINESS LEVEL TO [MRL 9] BY THE END PROJECT. IMPLEMENT [TEST PROTOCOLS] FOR [RAPID PREDICTION] OF STACK [LONG-TERM DURABILITY, ENERGY-EFFICIENT TESTING], AND [EARLY DETECTION] OF [OFF-SPEC] SUBCOMPONENTS.$41,186,672
· FY2025 · Department of Energy