EvolOH, an American hydrogen energy startup founded in 2020, specializes in low-cost and high-speed manufacturing of alkaline water electrolyzers for the production of green hydrogen. The company has built the highest throughput electrolyzer stack factories in the world.
Challenges: green hydrogen
Green hydrogen energizing the path to net zero
Hydrogen (H₂) is a crucial component in the production of ammonia, which is a key ingredient in many fertilizers, plastics, and other essential products. The majority of the world’s hydrogen (over 60 million tons) is produced via steam methane reforming (SMR) process. This process requires a significant amount of energy input and contributes about 2% of global carbon dioxide (CO₂) emissions. The SMR process emits between 5 and 9 tons of CO₂ per ton of hydrogen produced.
Hydrogen can also be produced through water electrolysis. Water electrolyzers typically include alkaline water electrolyzer (AWE), proton exchange membrane water electrolyzer (PEMWE), and solid oxide electrolysis cells (SOEC). If these electrolyzers use electric power from renewable energy sources, such as nuclear, solar, and wind, the hydrogen produced is referred to as “green hydrogen”. Green hydrogen can decarbonize hard-to-abate industries, such as steel manufacture, long-distance transportation, shipping, and aviation.
Green hydrogen is crucial for a carbon-neutral world.
Green hydrogen cost
The levelized cost of hydrogen (LCOH) is a variable that indicates how much it costs to produce 1 kg of hydrogen, taking into account the estimated costs of the investment required and the cost of operating the assets involved in its production.
Green hydrogen is not yet cost-competitive with SMR-produced hydrogen. The LCOH of gray hydrogen through SMR without carbon capture is below $1/kg, even assuming a natural gas price at $3.50/MMBtu. The LCOH of blue hydrogen produced through SMR with carbon capture ranges from $1.40/kg to $2.55/kg, depending on the technology used. The LCOH of green hydrogen is currently in the broad range of $3 - $7/kg, depending on several factors such as location, technology, and the cost of renewable energy.
However, it is anticipated that the LCOH of green hydrogen will decrease, making it cost-competitive with SMR-produced hydrogen. During the past two decades, the levelized cost of electricity (LCOE) for newly commissioned installations of PVs and onshore and offshore wind power decreased by 88%, 68%, and 60%, respectively. Technological advancements are anticipated to play a significant role in reducing the LCOH of green hydrogen.
Green hydrogen cost reduction
Modern alkaline water electrolysis currently provides the lowest LCOH among the three types of electrolyzers (proton exchange membrane water electrolysis and solid oxide electrolysis cells). They are highly efficient and able to handle the intermittent loads associated with renewable energy sources.
The diagram below depicts the working mechanism of a typical alkaline water electrolyzer.
Alkaline water electrolyzer has two electrodes operating in a liquid alkaline electrolyte solution of potassium hydroxide (KOH) or sodium hydroxide (NaOH). A diaphragm separates the electrodes, prevents the product gasses from crossing, and transports the hydroxide ions (OH⁻) from one electrode to the other.
Even though the government is supporting hydrogen projects with thousands of megawatts of power, the production of electrolyzer stacks is still only a few hundred megawatts. This difference makes it harder for hydrogen to be used as a base for new industries. To lower the price of green hydrogen and meet the demand, electrolyzer production needs to go up by many orders of magnitude.
EvolOH Technology
EvolOH develops a high-speed manufacturing of alkaline water electrolysis stack. Electrolysis cells are constructed with polymer sealants that cure rapidly within seconds. This facilitates the integration and stacking of electrolysis cells in a continuous production line. EvolOH is capable of producing over 1,000 megawatts of electrolyzer stacks in a year. EvolOH’s technology not only reduces the cost of the water electrolysis stacks but also enables their rapid deployment.
EvolOH electrolysis stack structure
The diagram below depicts the EvolOH’s electrolysis cell stack and fluid flow within it.