7. Innovation Leadership
Fulvio Federico
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thyssenkrupp nucera looks back at >30 years of leading innovation in modern industrial electrolysis
BM | CFI | ||||
First project on new | |||||
First Uhde Single Element Bipolar | |||||
UHDENORA JV among Uhde | tkUCE JV among thyssenkrupp | increased capacity | |||
Membrane electrolyzers | and | in 2001 | electrolysis and | , | 20 MW module |
merging also former Chlorine | |||||
Engineers Corp. in 2015 |
HCl-ODC2 | NaCl-ODC2 | e-BiTac v7 and | |||||
First industrial reference | Market Entry | BM Gen. 6plus | |||||
plant, energy saving | 25% energy saving CA | Latest high efficiency | |||||
hydrochloric acid recycling | electrolysis | electrolyzers | |||||
Power Consumption | |||||||
19841 - 1994 | 1997 | 2003 | 2012 | 2013 | 2018 | 2020 | 2021 |
Current Density (specific production capacity)
BM single element Gen.3 | BM single element Gen.6 |
First laser-weldedcell, | First Full Zero-Gap cell incl. |
internals made possible | flexible elastic element and |
acidified operation | combined with |
independent sealing |
BiTAC
World's first zero-gap cell which | AWE | CA |
made 6kA/m2 possible | ||
Carbon2Chem
AWE (Hydrogen)
Demo Plant 2 MW (stack portion of 10 MW unit)
1 GW p.a. fabrication
De-bottlenecked production
of 15,000 cells p.a.
1. Much longer experience before with mercury amalgam cells 2. Joint Development with Covestro and De Nora; ODC = Oxygen depolarized cathode; HCl = Hydrochloric Acid; NaCl = Sodium Chloride Developments with De Nora advanced coatings and half-shells / bipolar elements manufacturing
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Example | Successful implementation of disruptive innovations - unique advantage of thyssenkrupp nucera
energy saving compared to
25% conventional CA electrolysis
Gas Diffusion Electrode
Gas Diffusion Electrode (GDE) by De | Applied in large scale | Applied in NaCl-ODC |
Nora typically used in Fuel Cells | HCI-ODC electrolyzers | electrolyzers |
(2003) | (2013) |
Proprietary technology with joint development partners Covestro and Industrie De Nora; ODC = Oxygen depolarized cathode; HCl = Hydrochloric Acid; NaCl = Sodium Chloride
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thyssenkrupp nucera developing an industry leading electrolyzer cell design with De Nora
Contributions thyssenkrupp nucera
Design of cell, electrolyzer and balance of plants
Selection of separator (membrane/diaphragm)
Other parts including:
- Selection of corrosion resistant materials
- Current distribution & electrical contacts
- Gas-liquidfluids handling & distribution
- Sealing
- Adaptations for different operating conditions, procedures, concepts (e.g. with or without ODC)
thyssenkrupp nucera cell | Contributions De Nora | |
Anode and cathode catalytic coatings, and GDEs
- +
Manufacturing of half-shells
BM
(single element)
Holistic collaboration in cell design, electrochemical components and manufacturing process
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thyssenkrupp nucera's leading design and manufacturing know-how crucial in developing the AWE cell
Hydraulic design
- Improved hydraulic and fluid dynamics
- Optimized feed of reactants to the catalytic centres for effective kinetic of electrochemical reactions
- Design mitigates local concentration gradient for best efficiency and longevity
Electrical design
- Electrical current uniform distribution to the electrodes
- Uniform distribution by continuous laser welding
- Design minimizes ohmic losses
Mechanical design
- 100% leak proof cell throughout service life ensuring to avoid emissions any time
- Strong flange and bolts forces compressing the gaskets for superior sealing
- Design improves safety and environmental protection
Zero gap
- Combination of expanded-metal current distributor with a woven mesh cathode enables a "zero gap" over the whole membrane area
- Elastic element with compression independent from sealing
- "Zero gap" improves separator life and performance
Know-how and technologies needed for implementing effectively high current density and high efficiency1
1. Density and efficiency assessment based on Eurochlor data
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ThyssenKrupp AG published this content on 13 January 2022 and is solely responsible for the information contained therein. Distributed by Public, unedited and unaltered, on 13 January 2022 12:00:02 UTC.