Institute of Energy Technologies (IET)

Electrochemical Process Engineering (IET-4)

Stacks and Systems

About

In order to achieve the German government's climate targets, alternative energy storage systems and converters need to be developed and established in all energy-intensive sectors (such as industry, transport and households). Renewable energies and hydrogen as a storage medium play a decisive role in the necessary CO₂ reduction. The “Stacks and Systems” research group works at the interface between understanding the electrochemical, electrical, mechanical and fluid mechanical processes involved in electrolytic hydrogen production and the transfer of technologies to or further development with industry for the purpose of commercialization. The focus is on aspects such as efficiency and longevity in order to increase the economic viability of the systems.

Research Topics

Layout and design of components for electrolysis stacks and systems. In addition to a wide range of experiments, supporting tools are used to simulate the fluidic (CFD) and mechanical (FEM) behavior as well as various analytical methods (e.g. pressure distribution measurements).
Identification of scale-up effects in the transfer from small laboratory cells to stacks on a technically relevant scale (up to the MW class). Optimization factors for increasing performance lie, for example, in the manufacturing tolerances, the clamping concepts, the assembly process or in design details to achieve a homogeneous distribution of contact pressure, flow, electric current and heat.
Understanding the interactions of the layer structures during stack assembly and stack operation.
Influence of impurities in the feed water of the electrolyzer on performance and degradation behavior.
Development of safety concepts (HAZOP, FMEA) and operating protocols for 24/7 operation of the test stands and systems with full automation. The protocols cover the operating phases of system start-up, stack run-in, load profiles, monitoring of limits, emergency shutdown scenarios and stack shutdown.

Contact

Dr. Holger Janßen

IEK-14

Building 03.2 / Room Y110

+49 2461/61-5082

E-Mail

Publications

H. Janssen, M. Hehemann, E. Hoppe, W. Zwaygardt, M. J. Müller
Stack Test Facility for PEM Water Electrolysis up to 400 Kilowatt and Lessons Learned at Stack Scale-up
ECS Meeting Abstract MA2024-01 1868 (2024)
DOI: 10.1149/MA2024-01341868mtgabs

E. Hoppe, H. Janssen, M. J. Müller
Statistical Investigation of the Reproducibility of Stack Components in a PEM Water Electrolyzer
ECS Meeting Abstract MA2024-01 1869 (2024)
DOI: 10.1149/MA2024-01341869mtgabs

H. Janßen et al.
A facile and economical approach to fabricate a single-piece bipolar plate for PEM electrolyzers
International Journal of Hydrogen Energy 49 (Part C), 816-828 (2024)
DOI: 10.1016/j.ijhydene.2023.09.175

B. Emonts et al.
A Holistic Consideration of Megawatt Electrolysis as a Key Component of Sector Coupling.
Energies 15(10), 3656 (2022)
DOI: 10.3390/en15103656

U. Reimer et al.
Design and Modeling of Metallic Bipolar Plates for a Fuel Cell Range Extender
Energies 14(17), 5484 (2021)
DOI: 10.3390/en14175484

M. Sietmann, H. Janssen, M. Müller, W. Lehnert
An analysis of the imperfections and defects inside composite bipolar plates using X-Ray computer tomography and resistivity simulations
International Journal of Hydrogen Energy 46 (50), 25677-25688 (2021)
DOI: 10.1016/j.ijhydene.2021.05.078

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Last Modified: 13.02.2025