GEM and IPESE Reveal Key Insights in Electrolyzer Manufacturing and Operations

EPFL researchers recently published a comprehensive study in Joule, performing a life cycle assessment (LCA) of various electrolyzer technologies, entitled Comparative life cycle analysis of electrolyzer technologies for hydrogen production: Manufacturing and operations.

This research was undertaken by the Group of Energy Materials (GEM) under the leadership of MER. Jan Van Herle and the Industrial Process and Energy Systems Engineering (IPESE) led by Prof. François Maréchal, with additional contributions from visiting Prof. Manuele Margni. The work traces the impact from manufacturing through to operation, highlighting the potential of these technologies to transform energy systems with improved sustainability practices.

Hydrogen is increasingly recognized as an interesting energy carrier, particularly noted for its ability to store energy through electrolyzers, often referred to as a ‘renewable fuel of non-biological origin’, introduced by the paper lead contact Xinyi Wei, who is PhD student supervised by Jan Van Herle and Francois Marechal.

The research focused on various types of electrolyzers—Alkaline (AEL), Proton-Exchange Membrane (PEM), Anion-Exchange Membrane (AEM), and Solid Oxide (SOE). It assessed their environmental impacts throughout their entire lifecycle, from using raw materials in manufacturing processes to the system operations level.

Typically, the focus within the energy community has been on the operation and integration of electrolyzer systems with other technologies. This study begins with the fundamentals, examining the materials used at each step of the manufacturing process. It details the environmental impacts of materials, especially some critical raw material usage. It outlines potential alternatives that could set new directions for the future of electrolyzer manufacturing.

Indeed, a sole focus on the manufacturing process does not capture the full scope. This study expanded its boundary to explore the integration of electrolyzers with various renewable energy sources across multiple scenarios, spanning from the present to future years. The overall system efficiency was identified as a critical factor, particularly for its significant impact on climate change. Although the four types of electrolyzers have varying levels of technological readiness (TRL), which indeed impacts their life cycle assessment (LCA) performance, ultimately, as all technologies reach the same TRL, and also the costs of various electrolyzer technologies converge, efficiency will emerge as the critical factor in determining their competitiveness.

Furthermore, the study conducted a sensitivity analysis using EU Key Performance Indicators (KPIs). It’s well understood that the long-term operation of electrolyzers can lead to material degradation. Exploring how this degradation impacts efficiency and environmental performance provides another interesting highlight of the research.

Overall, the study emphasizes the critical need to integrate environmental, technical, and material considerations into the decision-making processes of industry partners, investors, and policymakers. This research establishes a foundation and a complete life cycle inventory for developing frameworks that can encourage broader adoption and optimization of electrolyzer technologies, ultimately in the quest for a sustainable energy future.

The list of authors: Xinyi Wei, Shivom Sharma, Arthur Waeber, Du Wen, Suhas Nuggehalli Sampathkumar, Manuele Margni, François Maréchal & Jan Van herle.