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Green hydrogenInnovations for water electrolysis
Our engineers develop technologies for the green transformation. Patents protect these innovations and strengthen their competitive position. One example is the patented “conductive spacer fabric as an electrode support” for industrial water electrolysis.
Because of these characteristics, the production of green hydrogen through electrolysis is considered a key technology for achieving the decarbonization of the economy.
The zero-gap electric cell
This is precisely where thyssenkrupp nucera's innovation comes in. “The electrolysis cells required to produce green hydrogen consist of two half-cells, each containing an electrode and separated by a membrane,” explains Dr. Niedziela. “To achieve particularly high efficiency, the distance between the electrode and the membrane must be as small as possible.” The zero-gap electric cell is the most effective design for this purpose, as the electrodes are positioned directly against the membrane.
To ensure that the electric current can be conducted reliably from the electrode to the back wall of the housing under the chemical conditions of the electrolysis process, one material is currently essential: nickel. “Conventionally, an elastic nickel element is clamped between the electrode and the back wall of the housing to ensure the required contact pressure between the electrode and the membrane,” says Niedziela. However, nickel is not an ideal solution, as extracting the raw material is associated with significant environmental impacts and high material costs. The thyssenkrupp nucera team has developed a solution to this problem.
Since 2019, thyssenkrupp nucera’s innovation entitled “Conductive spacer fabric as an electrode support” has been pending as a patent application. It is also being pursued as an international patent application. The invention reduces both the amount of nickel used in the cell and the effort required for assembly. “Instead of an elastic element made entirely of nickel, our systems use a spacer fabric made from plastic filament yarn inside the cell. This generates the contact pressure required to press the electrode against the membrane. The necessary electrical conductivity is achieved either through a metallic coating on the filament yarn or through metal wires woven into the fabric,” explains the expert. As an elastic element, the spacer fabric therefore performs two essential functions: providing elasticity and establishing electrical contact.
A small change with a major impact: thyssenkrupp nucera’s solution not only reduces the use of nickel and makes the system itself more environmentally friendly, but also simplifies the production of the electrolysis cell. The element no longer needs to be welded into place; it can simply be inserted.
Our patented process and the use of plastic filament yarn make the production and maintenance of electrolysis plants more cost-effective by eliminating the high cost of nickel.
This creates a significant cost advantage, making electrolysis plants - and therefore the production of green hydrogen - not only more resource-efficient, but also suitable for large-scale deployment. This is an essential prerequisite for using green hydrogen on an industrial scale and making a wide range of industries - from steel production to the mobility sector - more environmentally friendly.
The power of green hydrogen
Hydrogen is conventionally produced from natural gas. Splitting the gas into hydrogen and carbon dioxide generates large amounts of CO₂. Green hydrogen, by contrast, is produced through water electrolysis using electricity from 100 percent renewable energy sources. During electrolysis, electricity splits water into its components: hydrogen and oxygen. No CO₂ is produced.
Green hydrogen can not only be used in the kilns and blast furnaces of the cement and steel industries to reduce emissions; it is also a highly versatile chemical feedstock. As a key raw material for ammonia and methanol, it can be further processed into fertilizers and fuels.
There is therefore enormous potential to make numerous industries greener and significantly reduce global CO₂ emissions. For the technology to succeed worldwide, however, it must be cost-effective, resource-efficient and deployable on an industrial scale.