CO2-neutral energy carriers are a crucial factor for a more sustainable future. Exentis is advancing the energy transition with additive manufacturing of Electrolyzer plates. Our innovative additive screen-printing technology enables the production of micro precise parts that would be difficult or even impossible to achieve with traditional methods like CNC milling, pressing, or injection molding. Learn more about it in this blog.
The CAMPFIRE partner alliance, funded by the German Federal Ministry of Education and Research, is on a mission to develop sustainable solutions to use green hydrogen derived from ammonia as an energy carrier, both seasonally and locally.
Exentis is proud to play a key role in the “Ammonia-to-Hydrogen Refueling Station” project. The goal is to develop a facility that can produce refuel-ready hydrogen from green ammonia. This hydrogen will be used as fuel for trucks and buses, replacing environmentally harmful diesel fuel. Transport and storage of hydrogen can be challenging and dangerous due to its explosive reaction when combined with oxygen, as well as its large volume, which is a disadvantage for transport. Therefore, hydrogen is converted into liquid ammonia using the Haber-Bosch process, to allow easier storage and transport.
During reconversion, the splitting of ammonia into hydrogen and nitrogen through cracking, the extracted hydrogen contains residual ammonia. This ammonia must be filtered out via a multi-stage filtration process to ensure the hydrogen can be used as fuel. To achieve this, the CAMPFIRE project is developing an innovative, cost-effective membrane module that enables the filtration process. Additive manufactured micro precise Electrolyzer plates created by Exentis play a critical role in this module.
The Important Role of Electrolyzer Plates in Green Ammonia-to-Hydrogen Conversion
Before refueling, ammonia needs to be reconverted into hydrogen in a high-pressure hydrogen refueling station. During this process, residual amounts of ammonia remain, which are filtered out by the Electrolyzer plate using membrane technology. The mixture flows through the thin channels in the additively manufactured steel plate. At the channel ends, sealed with palladium foil, the residual ammonia cannot diffuse due to its molecular size and is thus filtered out. After this process, the pure hydrogen is available as fuel.
The hydrogen separation plate is a critical component integrated within the membrane module.
Advantages of Additive Screen Printing in Manufacturing Electrolyzer Plates
The advantage of Exentis’ additive manufacturing technology lies in its ability to manufacture extremely fine, thin functional structures in micro precise parts. Additionally, it eliminates several manufacturing steps required by traditional methods such as CNC milling, pressing, welding/bonding, and more. The fine channels in the Electrolyzer plate, responsible for reliable filtration, are printed directly into the plate in one single manufacturing step.
This printing-process involves three different screens: initially, the solid layers are printed, followed by the layers with channels, and finally, another solid layer is printed over the channels. These overprinted channels are straightforward to produce with additive screen-printing technology and remain perfectly intact even after sintering the metal green body. The steel part requires no post-processing, as the Exentis technology effortlessly achieves the necessary surface quality during the printing process.
In general, channels starting from 125 micrometers can be manufactured using Exentis technology. Furthermore, this technology is specifically designed for true mass production. The production systems are engineered for additive manufacturing of millions of parts per year on one system. The EX432i production system, equipped with 40 workpiece carriers, can produce 1,050 Electrolyzer plates made from stainless steel 316L (dimensions 71 x 71 mm) in a single 24-hour shift. This is an output of more than 40 hydrogen separation plates per hour, significantly outpacing traditional manufacturing technologies.
Intricate microchannels terminate on two surfaces of the hydrogen separation plate, their precise outlets visible
Innovation Meets Sustainability: Our Collaborative Path Forward
The prototype of a suitable Electrolyzer plate for the membrane module was developed collaboratively by Exentis engineers and 3D screen printing specialists, together with the Hydrogen and Fuel Cell Center (ZBT). Complex channels within the component ensure that the hydrogen can be reliably filtered. Leveraging Exentis’ expertise, advantages of the technology were incorporated early in the design process, enabling an efficient manufacturing process.
The great flexibility of Exentis technology allowed rapid implementation of design changes within the project; new screens that define the form of parts are available within 48 hours. Additionally, for Exentis technology almost any material available in powder form can be converted into a printable paste. This allows for nearly unlimited material choices, enabling perfect adaption of parts to their intended functionality. This is a crucial factor for development projects as well.
Conclusion and Summary
Among its diverse applications, additive screen printing is particularly well-suited for producing copper components with optimized geometries too, including intricate cooling channels essential for efficient engine cooling or precise thermal regulation. These examples highlight just a few of the numerous applications where Exentis additive manufacturing technology offers significant advantages.
Contact us; we are happy to inform you about the extensive possibilities of Exentis Industrialized Additive Manufacturing and find innovative solutions together.
As part of the energy transition, Germany is promoting zero-emission, renewable energies. For renewable energies to be suitable, they must be stored and harnessed effectively. The CAMPFIRE project focuses on the seasonal and decentralized production of ammonia from locally generated wind or solar power, air, and water, as well as its use as an innovative energy carrier for zero-emission maritime mobility and stationary energy supply. For more information about the project, please see link below.