ProEly

Development of a recyclable plastic design and scalable process technology for the resource-efficient large-scale production of cell frames for alkaline water electrolysis - Subproject: Process Development and Sustainability Assessment

Hydrogen is a key energy carrier for achieving climate neutrality — produced via electrolysis from renewable energy sources. The National Hydrogen Strategy calls for 10 GW of electrolysis capacity by 2030. In addition to stack scaling, automated manufacturing processes are critical. The cell frame — historically made predominantly from metal — offers significant potential for plastic substitution, as 200–300 cell frames are required per megawatt of electrolysis capacity. The goal of ProEly is to develop a circular-economy-compatible plastic construction approach and a scalable injection molding process technology for the high-volume production of thermoplastic cell frames for alkaline water electrolysis. A two-component approach (ElringKlinger) confines the use of cost-intensive high-performance thermoplastics to media-carrying areas, while the structural part — made from standard plastic — withstands pressures exceeding 30 bar. In addition, elastomer materials and sealing concepts are being developed. Innovative processes enable automated high-volume production with AI-based quality assurance. The consortium comprises ZSW, TU Dresden (ILK), ElringKlinger AG, AUMO GmbH and Symate GmbH; MOCOM, Ecoclean and Stargate are associated partners. At ZSW, an electrolysis stack is being tested as a proof of concept under pressure operation. Demonstrating circularity reinforces sustainability and resilience. ProEly thus makes a substantial contribution to the transformation of the energy sector.