Electrolysis plants

Development and production of pressurized alkaline electrolysis plants

EBZ Group pressurized alkaline electrolysis plants provide the optimum conditions for cost-effective production of green hydrogen with a high degree of efficiency on an industrial scale.

The basis for this is our extensive experience in toolmaking and the design, construction and commissioning of plants for series production in the automotive industry. Both areas are subject to the highest quality standards, enabling us to achieve series production of standardized, turnkey electrolyzer plants of consistently high quality.

Additionally, we possess competencies in the areas of chemistry, metallurgy, and plastics technology which enable us to meet the specific requirements of pressurized alkaline electrolysis in an optimum fashion.

The scientific basis for our electrolysis stack was developed over more than ten years at the Centre for Solar Energy and Hydrogen Research Baden-Wuerttemberg (ZSW). We have focused on this development at EBZ since 2022 and continue our close exchange with researchers at ZSW.

Electrolysis systems and stacks – from a single source, made in Baden-Wuerttemberg

EBZ provides holistic solutions for industrial hydrogen production, ranging from an innovative electrolysis stack to a complete modular overall system. Our containerized electrolyzer plant consists of two standardized 20 foot containers. One of the containers contains two powerful 0.5 MW electrolysis stacks in the innovative EBZ design, while the second container is equipped with the complete control technology, the power electronics, and the water treatment system.

A container system of this kind provides an electrical output of 1 MW. Flexible scaling of the plant is achievable, thanks to the modular structure. For example, five 1 MW modules are combined for a 5 MW project. We therefore enable the needs-based implementation of different project sizes – efficiently, space-saving, and designed for industrial use.

We also supply separate electrolysis stacks for complete customer-specific systems. Each stack has a rated electrical output of up to 0.5 MW and is designed for operation under pressure. The EBZ electrolysis stack can be seamlessly integrated into individual plant concepts, thus offering maximum flexibility for a variety of applications.

3D modell electrolysis system

The electrolysis stack is particularly distinguished by the following characteristics:

High energy efficiency: This is ensured through features such as highly functional active catalytic coatings.
High hydrogen output: Hydrogen output of up to 100 Nm³/hour can be achieved with a rated capacity of 0.5 MW.
Robustness: Durable stacks, a prerequisite in the hydrogen industry.
Pressurized electrolysis: Hydrogen production at a pressure of 30 bar(g) enhances efficiency and reduces additional investment costs of downstream compressors for hydrogen compression and hydrogen storage.
Modularity: Compact electrolysis stacks from EBZ can be designed for modular configuration for large-scale projects.
Safety: Certification to the highest safety standards and acceptance by the TÜV Süd technical inspection association.

Innovative and robust design

Our electrolysis stack impresses through its sophisticated and robust design, as this ensures a long service life and easy installation. The stack can be assembled efficiently, thanks to the reduced number of components, and this enables reliable series production.

We place our faith in the proven technology of alkaline electrolysis (AEL), but in a completely new form. Integration of the latest innovations, such as electrode design or the cellular frame sealing concept, has created an electrolysis stack which combines efficiency, maintenance-friendliness, and an extraordinarily long service life.

Our optimized stack structure enables us to service the electrolysis stack with particular ease. The modular construction and low number of individual components ensures rapid access to relevant components, minimizing downtimes and reducing operating costs.

Through the targeted use of high-quality, sturdy, and corrosion-resistant materials, we ensure that our electrolysis stack achieves a long service life, even under demanding conditions.

A key component of this technological advance is the patented cellular frame design which combines several functions in a single, innovative component. The cellular frame facilitates reliable sealing of the electrolysis stack up to a pressure of 30 bar and, additionally, also conveys the lye to the electrodes. Simultaneously, the cellular frame design ensures the safe and separate discharge of hydrogen and oxygen. In contrast to conventional solutions, the cellular frame functions without separate sealing rings during all these functions.

In addition, the pressure-bearing shell of the electrolysis stack is constructed with solid stainless steel. The conscious decision to use solid material instead of coated materials indicates a targeted goal of achieving robustness and a maximum stack lifespan.

Efficient hydrogen production through innovative electrode coating

Our electrode package sets new standards in hydrogen production. Through a specially developed, highly active catalytic electrode coating, we maximize the reaction surface and optimize electrocatalytic processes.

One decisive advantage of our coating is that we can completely dispense with platinum group metals. In addition to contributing to the sustainability and cost-effectiveness of our electrolyzer, this means it requires no critical raw materials. The coating of our electrolysis stack was developed by EBZ and applied in Ravensburg, Germany. As a result, we can guarantee consistently high quality.

Thanks to our technologically advanced coating, we achieve outstanding energy efficiency, and hydrogen production is achieved with minimum consumption of energy. This facilitates the efficient generation of green hydrogen while conserving resources.

[Translate to English:] Elektrodenbeschichtung

An overview of important performance indicators of our electrolysis stack

Efficient hydrogen production under pressure

Our electrolysis stack is specially designed for operation under pressure and, consequently, offers considerable advantages with regard to performance and efficiency. Pressurized electrolysis enables the achievement of higher energy efficiency and, simultaneously, reduces investment costs for downstream compression stages, as the hydrogen is already created with a high outlet pressure. This makes our electrolyzer particularly attractive for industrial applications and the hydrogen infrastructure.

Moreover, operation under pressure enables the realization of higher flow densities, a major advantage in dynamic load operation. This means that our stacks are ideal for intermittent operation, interacting with renewable energy sources. In contrast to classic alkaline electrolyzers operating under atmospheric pressure, our systems are distinguished by considerably higher flexibility and controllability, a decisive advantage for energy efficient integration in volatile electricity grids/networks.

Safety is the top priority during pressure electrolysis. Our electrolysis stack meets all relevant safety standards and is certified by the TÜV SÜD technical inspection association pursuant to the Pressure Equipment Directive.

Research and development

Continuous further development of our electrolysis technology is based on a solid scientific basis. For over a decade, the Centre for Solar Energy and Hydrogen Research Baden-Wuerttemberg (ZSW) devised the development basis for our electrolysis stack. We have continued this research work at EBZ since 2022, consistently driving the industrialization of the electrolyzer. As previously, EBZ maintains a continuous exchange with scientists at ZSW for further development.

To achieve targeted optimizing of our highly functional electrode coatings, we also have an electrode test stand with which we can efficiently examine the electrocatalytic activity of new coatings.

Moreover, EBZ is involved in the Ely2Series, Megastack BW and AEMELHy support projects:

EBZ electrolyzers meet the requirements of the European Hydrogen Bank

With an EBZ electrolyzer, our customers meet the guidelines for procurement of electrolyzers and all other specifications for participation in European Hydrogen Bank auctions.

In the context of the publication of requirements and conditions for the Innovation Fund IF24 Auction of the European Hydrogen Bank on September 27, 2024, it was, among other things, determined that purchases of electrolysis stacks from China are limited to 25% of the installed electrolysis performance (in MW_el). An electrolysis stack is determined to be produced in China if the production of cells, surface treatment, or assembling of stacks occur in China.

All components for EBZ Group electrolyzers are obtained exclusively within Europe. Moreover, both manufacturing and coating of electrode packages and the assembling of stacks occur at our main location in Ravensburg, Germany. EBZ also places enormous emphasis on including local enterprises in the value chain and, consequently, actively strengthening Baden-Wuerttemberg as a business location.