AI and hydrogen are the focus of this year’s Hannover Messe. H2‑international’s trade fair preview is showing what’s new to see at the Hannover Messe and especially Hydrogen + Fuel Cells Europe.
The transformation of industry towards climate neutrality is gaining more and more momentum. Which is why the decarbonization of industry is also at the center of interest at this year’s Hannover Messe. The energy industry has a crucial role to play in this. The transformation is based on two drivers: artificial intelligence (AI) and hydrogen. Because it is clear that a climate-neutral industry without a hydrogen economy is inconceivable.
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Over 500 exhibitors on the topic of hydrogen will be represented at Hannover Messe 2024. Most of them in the context of the Hydrogen + Fuel Cells Europe fair in Hall 13. Also this year’s partner country, Norway, with its motto “Pioneering the Green Industrial Transition,” is putting carbon-neutral production and new digital solutions in focus at its hydrogen pavilion (Stand D30). Likewise under the banner of the hydrogen economy is the Norwegian-German energy conference “Renewable Dialogue – North Sea Energy Hub,” which will take place in the Convention Center April 23, 2024. This conference particularly aims to concretize business models of the H2 economy. Hydrogen is also a central component of the All Electric Society Arena. This arena is directly connected to the ZVEI stand in the middle of Hall 11, Stand B58.
What products, services and business models the hydrogen economy already offers today will be shown by exhibitors of Hydrogen + Fuel Cells Europe. Important players and innovations H2‑international is introducing in this trade fair preview.
Fuel cell technology
Proton Motor Fuel Cell GmbH is presenting at the Hydrogen + Fuel Cells Europe its fuel cell system HyModule S4. It is conceived for stationary applications in residential buildings and small industrial complexes and as an emergency or off-grid power supply. The device offers a lower power range of 4.1 kWel and an output voltage range of 28 to 55 VDC. The H2 supply pressure is 1.5 to 7 bar. The HyModule S4 uses the liquid-cooled FC technology HyStack 200 from Proton Motor and can be used in an ambient temperature of 5 to 40 °C.
Fig. 2: The FC system HyModule S4 for stationary applications, Source: Proton Motor, Proton Motor, Halle 13, Stand E34
The automotive group Honda is coming to Hannover with the prototype of its new fuel cell module. The module is designed for H2 cars, commercial vehicles, construction machinery and stationary power generators. The fuel cell in compact dimensions has a high output power and a fast start-up time, even in environments with low temperatures. For use in heavy-duty commercial vehicles, Honda has already begun, together with Isuzu Motors, to test the fuel cell drive of the next generation. A prototype is already out on public roads. The launch of a series model is planned for 2027.
Fig. 3: The FC module FCS-26 from Honda is also suitable as a clean and quiet emergency power source, Source: Honda Honda, Halle 13, Stand C56
SFC Energy, manufacturer of hydrogen and methanol fuel cells, has expanded the performance class of its mobile solution Efoy H2Genset. The mobile solution is intended as an alternative to conventional diesel generators. It can be used for a multitude of applications, e.g. on construction sites, at events, at festivals and in remote locations with temporary power requirements.
Fig. 4: Mobile fuel cell device for use on construction sites or at festivals, Source: SFC Energy, SFC Energy, Halle 13, Stand C04
Ballard Power Systems does not have its own presence at this year’s Hannover Messe. However, the company is part of a Canadian delegation participating in a joint presentation of over 300 exhibitors from 25 countries in the field of hydrogen and fuel cell technology. Currently, there are nearly 4,000 trucks and buses worldwide driven with fuel cells from Ballard (see also p. 61). The fuel cells are also used in several hydrogen ships, trains and hydrogen projects with global partners. At the Hannover Messe, Ballard will be temporarily represented in the Canadian pavilion by an expert in fuel cell technology.
Ballard Power, Halle 13, Stand D40
Hydrogen supply
AEG Power Solutions equips hydrogen plants with direct current supply systems. The company’s electrolyzer power supply is designed to provide stable current and power over a wide voltage range. It is suitable for the production of green hydrogen with fluctuating renewable energy sources, as these electrolyzer converters offer high DC dynamics and high efficiency in terms of grid conformity, even in partial load operation. To reduce space requirements, installation time and costs, AEG Power Solutions offers scalable plug & play solutions. These solutions can comprise up to eight DC-3 modules in parallel, which deliver up to 16 MW, 1,500 VDC and 25.6 kADC.
Fig. 5: The plug & play electrolyzer power supply comprises up to eight DC-3 modules, Source: AEG Power Solutions AEG Power Solutions, Halle 13, Stand B45
The company Siqens has developed an electrochemical hydrogen separation technology (EHS). In contrast to the electrolysis of water, the company wants to use it to produce hydrogen from biogas, methanol or methane. According to the manufacturer, the EHS process also allows the separation of hydrogen from natural deposits. Another application is the separation of hydrogen that will be transported via the natural gas grid.
Fig. 6: The EcoCabinet from Siqens, Source: Siqens, Siqens, Halle 2, Stand A42
Fuel cell and electrolyzer components
The new humidifier HumidiPower from Pentair is designed for PEM fuel cells. It acts as a heat and moisture exchanger. According to the manufacturer, the device has a patented, spiral-wound hollow fiber design, to ensure efficient moisture transfer to air and other gases. A low pressure drop should minimize energy consumption. The moisture removed from the exhaust gas of the fuel cell is reused in the purge gas.
Fig. 7: The HumidiPower ensures sufficient moisture in the PEM fuel cell, Source: Pentair, Pentair, Halle 13, Stand F46
Parker Hannifin is showcasing the latest developments in the field of fuel cell technology at its stand. At an interactive table, visitors can take a look inside an electrolyzer receptacle and search for Parker components in it. New is the horizontal gas filter Peach Gemini PuraSep. The filter contains two stages and two drums each. The upper drum is used to separate solids and liquids, while the lower drum collects the liquid. Some of the solids flow into the lower drum below the first stage, but most of the solids collect on the elements and on the bottom of the upper barrel of the first stage. Likewise new is a humidifier for FC vehicles and the H70-08-HRS hoses for H2 applications.
Fig. 8: At an interactive table, visitors can take a look inside an electrolyzer receptacle and search for Parker components in it Source: Parker Hannifin, Parker Hannifin, Halle 13, Stand C55
Fischer Fuel Cell Compressor from Switzerland manufactures air compressors for fuel cell systems. Their special storage technology should then enable high performance and efficiency even when the fuel cell system is operating at high altitudes. Therefore, in addition to the classic FC applications in vehicles, trains, ships or stationary units, the compressors also have a place in aviation. The devices are not only in test mode, but are also in flight operation for several hours at a time. The company has also expanded its annual production capacity to 5,000 units.
Fig. 9: Compressors from Fischer are also suitable for aviation, Source: Fischer Fuel Cell Compressor Fischer Fuel Cell Compressor, Halle 13, Stand E46
Also the Danish specialist for FC compressors Rotrex is presenting a new air compressor. The EK40CT-2429 has an additional turbine/expander unit. This new compressor should be suitable for stationary, maritime and aerial applications with large fuel cell stacks with up to 400‑kW output power.
Fig. 10: The new fuel cell compressor from Rotrex, Source: Rotrex, Rotrex, Halle 13, Stand C15
The Swiss company Celeroton Fuel Cell is developing and producing ultrahigh-speed turbo compressors and drive systems for fuel cell applications. All FC compressors from Celeroton are equipped with their own developed gas bearings that should enable high efficiency, oil-free operation and a long service life. With the CTi-1100, the company presents the second generation of the turbo compressor with integrated inverter for intralogistics, range extenders, stationary systems and drones. Likewise new is the CTi-2001 with integrated 80‑V inverter, conceived for intralogistics and off-road applications.
In addition, Celeroton Fuel Cell is expanding its product palette for applications with high power ranges. The new turbo compressor CTE-4000 in conjunction with the inverter CC-4000 should provide the air supply for fuel cells with a net output of 100 to 200 kW. The new system will be equipped with an optional turbine expander and several aerodynamic variants.
Fig. 11: Turbo compressor with 100 to 200 kW net output, Source: Celeroton Fuel Cell, Celeroton, Halle 13, Stand D49
PDC Machines from the USA produces membrane compression systems and hydrogen compressors. Via the new online portal MyPDCMachines.com, customers can manage a digital operation twin of their installed PDC system. The portal offers access to important information, like the device status, recommended maintenance schedules, operation reports, service history, handbooks and data sheets. In addition, it enables the ordering of replacement parts. New is also a “PDC Toolbox,” which should help customers in the service or maintenance of PDC compressors.
Fig. 12: Access by QR code to the online portal MyPDCMachines, Source: PDC Machines, PDC Machines, Halle 13, Stand E50/2
The gas analysis specialist Archigas from Rüsselsheim is presenting a novel measuring technology for humidity-independent H2 detection. For it, the company, in cooperation with the university Hochschule Rhein-Main, newly implemented the thermal conductivity measurement principle and combined it with semiconductor technology. With under 30 milliseconds, the new sensor from Archigas should exhibit an especially high reaction speed. If condensation comes in contact with the sensors for gas analysis, this usually leads to their immediate destruction. As a consequence, water can appear in the various places of the H2 process chain, security gaps can result and high costs can accrue. The special construction of the measuring module should therefore effectively combat a contact of condensate with the sensory units.
Fig. 13: As hydrogen is highly reactive, a detection over the whole process chain should be followed in real time Source: Archigas, Archigas, Halle 13, Stand C16
Hydrogen refueling pumps
This year, Maximator Hydrogen is introducing its newest generation of hydrogen refueling pumps. The Max Dispenser 1.5 has a multimedia display with touch function, microphone, loudspeaker and NFC reader for direct payment. This enables users to receive precise refueling instructions and see the filling status of their vehicle. At the same time, the display serves as an interface to 24/7 support, which is always available to answer users’ questions.
Thanks to the built-in tilt detection, the dispenser is set to a safe state in dangerous situations, like for example impact with a vehicle. The H2 inflow is stopped, the relief valve is opened and the dispenser is de-energized. The dispenser can fill cars and heavy-duty vehicles with 700 bar or 350 bar.
Fig. 14: Thanks to the built-in tilt detection, the dispenser is set to a safe state in hazardous situations Source: Maximator Hydrogen, Maximator Hydrogen, Halle 13, Stand C26
Also Linde is introducing a new hydrogen refueling pump at the Hydrogen + Fuel Cells Europe. The HyQ-Dispenser should offer high performance in H2 refueling. It is also said to be energy-efficient, very quiet and optimized for maintenance work.
Fig. 15: Card payment at the new Linde hydrogen refueling pump, Source: Linde, Linde, Halle 13, Stand D55/1
Components for hydrogen refueling pumps
Norgren under its brand Buschjost now offers H2 high-pressure solenoid valves with FM-approved coils for the North American market. The company can now serve customers who are building hydrogen refueling stations or hydrogen storage facilities for Korea, China, Europe or the USA. The valves are designed for a pressure of up to 1,050 bar.
New are also oxygen solenoid valves and regulators that the company has developed specifically in accordance with industrial gas standards for electrolysis applications. In addition, the company offers electric high-pressure proportional regulators for hydrogen refueling pumps.
Fig. 16: High-pressure solenoid valve with FM-approved coils for the North American market Source: Norgren, Norgren, Halle 13, Stand E13
Also Eugen Seitz from Switzerland is coming to Hannover with a new solenoid high-pressure valve for hydrogen applications. The valve has an integrated position indicator, which should ensure optimum system status information.
Fig. 17: The new H2 solenoid high-pressure valve with position indicator, Source: SeitzValve, Eugen Seitz, Halle 13, Stand D50
Bürkert is putting in focus with its trade fair appearance the new coil technology “Kick and Drop.” This technology is said to achieve energy savings of up to 80 percent in valves, 45 K less self-heating and 200 percent more switching pressure compared to conventional coils. The Kick-and-Drop coil is equipped with a double winding of an inrush and holding winding. In Kick-and-Drop electronics, the coil is excited by a high electric impulse. This generates the required inrush power that the valve needs to open. After around 500 milliseconds, the Kick-and-Drop electronics switch to an energy-saving holding mode. With this, the power consumption is drastically reduced.
Fig. 18: Kick-and-Drop coil from Bürkert, Source: Bürkert, Bürkert, Halle 13, Stand C30
Research
The German aerospace center for technical thermodynamics (DLR-Institut für Technische Thermodynamik) will be represented at the Hydrogen + Fuel Cells Europe with its departments for energy system integration and electrochemical energy technology. The institute develops electrochemical reactors based on proton ceramics. Proton ceramic fuel cells are operated at temperatures between 400 and 600 °C. The electrode configuration separates the vapor supply from the hydrogen production and thus prevents a dilution of the two streams. These novel cells are versatile: They can supply electrochemically compressed hydrogen, they can enable the protonation of molecules such as CO or CO2 into valuable raw materials, and they can additionally be used as conventional fuel cells for energy supply.
In the PtX-Wind partial project of H2Mare, the DLR is researching the offshore production of green hydrogen and power-to-X products. At the trade fair, the research institute is also introducing the transportable platform XPlore. This serves to investigate various electrolysis technologies in combination with different synthesis technologies.
Fig. 19: The transportable platform XPlore serves for offshore tests, Source: DLR (based on CAD from TUB-EBMS) DLR, Halle 13, Stand B36
The ZBT in Duisburg (Zentrum für BrennstoffzellenTechnik) is putting its focus on electrolysis and hydrogen derivatives at this year’s trade fair. The research institute is showing a model of an ammonia cracking reactor that was produced using 3D metal printing. A to-scale model of the associated cracker system for mobile applications will also be on display. The system was designed for a sailing yacht and now installed as part of a complete ammonia ship propulsion system in the sports yacht Ammonia Sherpa.
Fig. 20: Ammonia cracker system for use on a sailing yacht, Source: ZBT
The electrolysis division of the ZBT is presenting new precious metal-free membrane electrode units and introducing methods for the quality control of PEM electrolyzers. In the field of material qualification, the ZBT is demonstrating methods for the characterization and detection of damage phenomena on fuel cell components such as membrane electrode units or coatings on bipolar plates. ZBT, Halle 13, Stand E40
Fraunhofer ISE is presenting a laboratory AEM electrolysis cell in Hannover. This is a further development of the PEM electrolysis cell design and will be used for the precise characterization and qualification of various components such as membranes, porous transport layers and catalysts. This happens at pressures of up to around 10 bar, increased current densities of over 5 A/cm² and under precise temperature control by an integrated heater. The institute also offers customers measurement services for PEM and AEM electrolyzers and an analysis of the measurement results, to identify opportunities to improve customer products.
A new design of membrane electrode assemblies (MEAs) for electrolysis and mobile fuel cells, manufactured using screen printing or slot die processes with commercially available materials, is also part of the trade fair presentation.
Fig. 21: New design of the MEA for electrolysis and mobile fuel cells, Source: Fraunhofer ISE Fraunhofer ISE, Halle 13, Stand C41
At this year’s Hannover Messe, Fraunhofer IMM is introducing, at the Fraunhofer joint stand (Fraunhofer-Gemeinschafsstand), a compact system for ammonia splitting. This can be used for the decentralized supply of hydrogen, for example for hydrogen refueling stations. In maritime applications, such a system can supply fuel cells with hydrogen or supply ignitable “split gas” for ship engines.
The theme at the special exhibition area (Sonderausstellungsfläche) of the Hydrogen + Fuel Cells Europe is power-to-gas processes such as methanation in compact, microstructured reactors. In addition, Fraunhofer IMM is introducing reformer systems with which hydrogen carriers, like methanol, ethanol and synthetic hydrocarbons, can be used for hydrogen-based stationary and mobile energy supply. For these reformer systems, the institute is developing catalysts and catalytic coatings for microstructures.
Fig. 22: The ammonia and methanol-based systems for stationary and decentralized energy supply can be seen in Hall 2, Stand B24 Source: Fraunhofer IMM, Fraunhofer-Gemeinschafsstand, Halle 2, Stand B24, Fraunhofer IMM, Halle 13, Stand C47/1, Sonderausstellungsfläche
Machine building
The special machine manufacturer Graebener Maschinentechnik is presenting a press for the production of alkaline electrolyzer stacks. The pre-assembled stack consisting of bipolar plates is first inserted into the machine. There, it is compressed to a defined height until a certain pressure is reached within the stack. This pressure must then be maintained unchanged for several hours. During this time, the stack can be subjected to all the necessary technical tests with the help of other procedures.
The stack press for electrolyzers has a force of 800 metric tons and can accommodate stacks with a maximum height of around 3 m, a maximum diameter of 1.60 m and a weight of up to 12 tonnes. In order to be able to guarantee assembly work with maximum safety during operation, a hydraulic drive was deliberately dispensed with. Instead, the stack is compressed inside the press using six servomotor-driven spindle units. These are operated in synchronization mode and should therefore enable particularly homogeneous compression of the stack.
Fig. 23: The new stack press for electrolyzers, Source: Graebener Maschinentechnik, Graebener Maschinentechnik, Halle 13, Stand E42
The laser welding specialist AWL-Techniek Holding from the Netherlands develops laser welding equipment and complete production lines for bipolar plates. According to the manufacturer, the new laser micro-welding cell can achieve a focus of 0.052 mm and therefore weld at high speed. This enables the sophisticated welding of the wafer-thin bipolar plates.
Fig. 24: In the Experience Center, AWL has set up a test facility that also enables automated quality control of the bipolar plates Source: AWL, AWL-Techniek, Halle 13, Stand F49
The Belgian company Borit specializes in forming, cutting, welding and sealing technologies required for the production of metal bipolar plates for fuel cells and interconnects for electrolyzers. The trend with bipolar plates, according to Borit, is ever thinner materials on the order of 50 to 100 micrometers, in order to save weight. Borit develops the right technologies for such materials.
Fig. 25: Bipolar plates from Borit, Source: Borit, Borit, Halle 13, Stand C19
Maceas, a 100-percent subsidiary of Worthmann Maschinenbau, focuses on helium leak testing in vacuum and under atmosphere as well as ultrasound gas bubble detection in water bath. The company is active in the areas of hydrogen, electrolysis, fuel cells and battery components as well as heat storage technology. In Hannover, the company is showing a new fully automated helium vacuum tightness testing system for metallic and graphitic bipolar plates.
Fig. 26: New system from Maceas for leak testing of bipolar plates, Source: Maceas GmbH, Maceas, Halle 13, Stand E53/1
Catalysts and membranes
Pajarito Powder has built a new production facility for catalysts in fuel cell and electrolyzer stacks at its headquarters in Albuquerque, New Mexico, USA. The company uses platinum-group metals in its catalysts to achieve high performance and good stability and durability. With the new production facility, Pajarito Powder has tripled the production volume for FC catalyst material and doubled its in-house production of catalysts for the generation of green hydrogen.
Fig. 27: New production plant for significantly higher capacity, Source: Pajarito Powder, Pajarito Powder, Halle 13, Stand A40
The Chinese manufacturer Anhui Contango New Energy Technology is showing in Hannover a large-format catalyst-coated membrane (CCM) on various PEM variants. The CCM should have a high current density and a low iridium and platinum content. Contango supplied around 20 MW of CCMs to large Chinese water electrolyzers last year. According to the provider, the product is also interesting for European customers.
Anhui Contango New Energy Technology, Halle 13, Stand A21
Carbon Energy Technology from China produces composite membranes. The company’s new product consists of an organic polymer, ceramic powder and a carrier material. The membranes are available in thicknesses of 200 and 500 µm. They are used for the alkaline electrolysis of water, as they can efficiently separate hydrogen and oxygen and allow the electrolyte to pass through.
Carbon Energy, Halle 13, Stand A42
System integrators, operators and consultants
H2Apex with headquarters in Rostock/Laage is based on three pillars: The company is active as a system integrator for turnkey hydrogen projects and mobility solutions. In addition, the company produces green hydrogen. The third pillar is the development and production of compressed gas storage systems for the temporary storage of hydrogen.
Fig. 28: Container with H2 compressed gas storage tanks, Source: H2Apex, H2Apex, Halle 13, Stand E49
The hydrogen core grid should be in operation by 2032. For this, natural gas pipelines are to be converted to hydrogen and new hydrogen pipelines are also to appear. German natural gas grid operator Ontras is contributing its starting grid H2-Startnetz to the project. Among other things, it consists of the two IPCEI projects “Green Octopus Mitteldeutschland” and “Doing hydrogen.” With it, Ontras wants to lay the foundation for efficient and safe hydrogen transport in its grid area. The eastern German company is connecting via its infrastructure the whole German with the European network – the European Hydrogen Backbone. Via this, hydrogen produced in Scandinavia is to make its way to Germany.
Fig. 29: The Ontras H2-Startnetz consists of the projects “Green Octopus Mitteldeutschland” and “Doing hydrogen” Source: Ontras, Ontras, Halle 13, Stand D10
Siemens has expertise in the entire H2 value chain. The company makes this expertise available to OEM manufacturers, general contractors and plant operators as well as governments and municipalities in the implementation of hydrogen projects. This starts with financing and continues with the concept design and construction through to the operation of hydrogen generation plants and PtX projects. Siemens sees its strengths in the areas of digitalization, automation and electrification.
Siemens, Halle 13, Stand C36
The consulting firm PGUB Management Consultants is being represented in Hannover at the joint stand Hzwo-Gemeinschaftsstand Sachsen. PGUB advises the Swedish fuel cell manufacturer FCT Sweden. Under the name Protonik GmbH, starting April, an independent hydrogen consulting company is to be active. This is likewise to be found at the Gemeinschaftsstand Sachsen and also at the stand for the energy agency of the state of Hessen (hessische Landesenergieagentur, LEA).
Things had quietened down on the Bonhoff front. But then new information surfaced in February 2024 which prompted German transportation minister Volker Wissing to take action. On Feb. 15, he released Klaus Bonhoff, head of the policy issues department, from his duties with immediate effect and also moved a divisional head. The reason behind the decision lies in a discrepancy uncovered during an internal review undertaken by the transportation ministry, also known as the BMDV. The affair gained added force when German news magazine Der Spiegel reported on Feb. 20 that Wissing had stopped “completely the approval of hydrogen funding.” Yet in reality funding is not being axed. The ministry is merely carrying out reassessments that could lead to a delay.
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But one thing at a time. In this article we’ll attempt to shed light on who did what to whom as well as how and when it all happened.
It started back in summer 2023 when German business paper Handelsblatt published an article about a questionable friends and lobbying network. The suspicion of nepotism that was raised on various sides was based on the alleged existence of an overly cozy network of contacts linking a number of different political and industry figures. Bonhoff was reproached for his reported friendship with Werner Diwald, chairman of the German hydrogen association, and its president, Oliver Weinmann, both of whom he allegedly joined on a ski trip. What’s more, it was claimed that Bonhoff helped the German hydrogen association, abbreviated to DWV, to gain funding in 2021.
Stefan Schnorr, state secretary at the German transportation ministry, was tasked with clarifying the facts and, according to Der Spiegel, gave the all-clear a few weeks later, stating there was “No trace of favoritism.” At the same time, Bonhoff received broad support, particularly from the hydrogen sector.
Everything bubbled up again in early 2024 when Der Spiegel quoted parts of an email exchange between Bonhoff and Diwald (see freedom of information website www.fragdenstaat.de). This apparently substantiated a high degree of closeness and familiarity between the two men.
Inconsistencies and contradictions
In fact, what the disclosed emails show is that certain wishes and views regarding funding measures had been articulated on the part of the DWV. For example, Werner Diwald wrote in September 2021: “In view of the upcoming elections it would certainly be good for grant approval to be given before the end of this legislative period.” (Der Spiegel, Feb. 6, 2024)
This prompted Bonhoff to forward the email to the appropriate specialist department at the transportation ministry where he inquired after the state of affairs, according to the statement he gave to H2-international. As Der Spiegel and Tagesspiegel Background, another German publication, both reported, he also “orally supported” the project. However, given this expression of support was previously denied, this admission could now cause no end of trouble for the ministry.
LobbyControl then took it as proof that favoritism was indeed at play. On Feb. 16, 2024, the online platform stated that days before the ministry had conceded there were “inconsistencies and contradictions” in the allocation of funding and that is why minister Wissing relieved department head Klaus Bonhoff from his duties.
“The necessary relationship of trust between the minister and the head of department no longer exists.”
Stefan Schnorr, state secretary at the German transportation ministry, in the Frankfurter Allgemeine Zeitung (FAZ)
Furthermore, LobbyControl criticizes what it sees as the inadequacy of compliance rules at the transportation ministry and Bonhoff’s lack of a clear-cut separation between his personal and official contacts when it comes to grant allocation.
Overly cozy network?
Klaus Bonhoff, who is also known as “Mister Hydrogen” due to his extensive experience in leadership roles in the H2 and fuel cell sector, had previously worked for many years on fuel cell cars at Daimler before becoming managing director of Germany’s National Organisation Hydrogen and Fuel Cell Technology, or NOW, in 2008 (see HZwei, April 2011 & H2-international, October 2019). From there he transferred to his post at the German transportation ministry. His successor at NOW since May 2020 has been Kurt-Christoph von Knobelsdorff (see H2-international, February 2021).
Thanks to his considerable expertise, he was a popular and long-standing contributor at numerous industry events since he was well known as an adept public speaker with a skill for highly diplomatic and precise wording. It’s understandable that the DWV in particular wanted to get close to him given that the association comprises many major German industrial corporations from the H2 community and Bonhoff, in his role as NOW spokesman, was the main point of contact for funding applications in the hydrogen sector. However, the responsibility for awarding funds, both then and now, lies with the project management agency Jülich (PtJ).
The DWV’s role
Over the years, the DWV has developed – especially under the leadership of Werner Diwald – from a highly committed body of motivated idealists to an industrial lobbying group. Because of this change, some of the original members who prefer an idealistic approach have turned their back on the association in the past few years. Some of them have urged repeatedly for less dependency on industry and greater levels of transparency. Most recently, Johannes Töpler, who was a long-serving chairman of the DWV, resigned from his post as the DWV’s education officer at the turn of the year. Among the reasons for his resignation was that he no longer thought education and training, a crucial area in his view, was receiving the appropriate attention and appreciation it deserved within the work of the association.
In terms of legal form, the DWV is officially a registered association. Over the years, Diwald has worked to set up various expert commissions to which participating companies pay high-level contributions. This enables the DWV to represent their interests, including on the political stage in Berlin and Brussels. As such, political evenings and business talks are organized on a regular basis where political and industry representatives can meet, as commonly occurs in associations nowadays. One of these expert commissions, HyMobility, was awarded millions of euros in funding in 2021 via the PtJ, i.e., from the transportation ministry’s budget, something which Bonhoff is now being reproached for.
The ministry confirmed to H2-international: “The HyMobility innovation cluster is supported by the Federal Ministry of Transport and Digital Infrastructure as part of the national hydrogen and fuel cell innovation program. The grant is up to €1,438,600. The calculation is based on actual expenditure up to the maximum grant level. […] The HyMobility cluster is financed through grants, contributions for cluster membership, and a proportion of the membership contributions of the DWV. […] The funding project facilitates cluster management, cluster coordination, the support and guidance of the expert commission’s work as well as the preparation of findings from the expert commission and from the expert committees and the provision of recommended courses of action to meet further development needs. In addition, the funding covers the venues for cluster meetings, the creation of studies and analyses as well as technical and legal reports. […] The funding is allocated for specific purposes.”
HyMobility’s aims, according to its project outline, include: “Involvement in the formulation of relevant policy and legal conditions at a national and European level for the market preparation and introduction of low-carbon mobility based on renewable hydrogen. […] the creation and strengthening of understanding for and trust in innovative and low-emission vehicle technology based on renewable hydrogen within transport and national and European politics.”
In connection with this, the DWV confirmed to H2-international that the goals of the expert commissions are to “attract attention for the particular topic, raise awareness, bring together stakeholders from the relevant areas and sectors, prepare joint positions and recommend courses of action to policymakers.
LobbyControl makes the following criticism in relation to this: “It is unusual and questionable that an industrial lobbying association such as the DWV should receive a state subsidy for work that it would carry out regardless: maintaining networks and lobbying.”
“The HyMobility project is supported by the Federal Ministry of Transport and Digital Infrastructure through a total of EUR 1.8 million in funding as part of the national hydrogen and fuel cell innovation program. The funding guidelines are coordinated by NOW GmbH and executed by the project management agency Jülich (PtJ).”
https://dwv-hymobility.de/organisation/
Bonhoff told H2-international: “HyMobility is funded in the same way that the environment ministry funds the HySteel project which was approved prior to HyMobility.” Tagesspiegel Background reported on this very subject on Feb. 7, 2024: “The ministry [German environment ministry; editor’s note] is satisfied with the project. ‘Such networking is effective and successful, is conducive to the sharing of best practice and the establishment of horizontal and vertical partnerships in research, testing and production.’”
Among the 22 members of HyMobility are NOW and H2 Mobility Deutschland. H2 Mobility is a consortium of various automotive, industrial gas and petroleum companies plus an investment fund focused on the construction of hydrogen refueling stations in Germany. Practically every station that is built and managed by this Berlin-based company is subsidized to the tune of nearly 50 percent from European funds or the funds of German central or regional government. One of the three directors is Lorenz Jung (see H2-international, October 2023), who took up the role in April 2023. According to information from LobbyControl, he is the son-in-law of Oliver Weinmann. Jung, whose wife (Weinmann’s daughter) works at NOW in the communications department, has been a manager at the company virtually since its inception.
The roles of Weinmann and Diwald
Weinmann is a founder and board member of what was then the German hydrogen and fuel cell association (see HZwei, October 2010). Born in Hamburg, he had initially worked for city’s electricity company (Hamburgische Electricitäts-Werke or HEW) which was taken over by Swedish corporation Vattenfall Europe when it became the majority shareholder in 2001. Weinmann held the position of managing director at Vattenfall Europe Innovation GmbH from 2010 to July 2023, followed by head of innovation management at Vattenfall Europe AG. From 2020 onward he has also worked in a voluntary capacity as the president of the DWV. In addition, he is chairman of the NOW advisory council, vice chairman of the hydrogen body Wasserstoffgesellschaft Hamburg and holds or has held – according to his own HyAdvice website through which he offers freelance consulting services on matters including funding – further leadership positions at various organizations, among them Hydrogen Europe and the Energy Storage Systems Association or BVES.
Oliver Weinmann at a parliamentary evening in Berlin in 2022
Similar to the way Weinmann operates with his HyAdvice consulting business, Diwald offers his services through PtXSolutions, formerly known as ENCON.Europe. The company is the vehicle through which the DWV chairman provides consultation as a sideline to institutions such as the DWV, Encon Energy EOOD (ENCON subsidiary), Enertrag (former employer), NOW, Performing Energy (DWV think tank) and Vattenfall Europe Innovation. Originally, ENCON.Europe had undertaken some work for the DWV (see H2-international, October 2020). According to a statement by Diwald, ENCON.Europe at the time played a considerable part in increasing the visibility of the DWV without itself appearing in the limelight. He says the company positioned the DWV and the Performing Energy expert commission exclusively as brands in the political sphere and negotiated in the interests of the association. From 2017, the company’s staff included Dennitsa Nozharova, Werner Diwald’s wife, who at the same time also worked for the DWV and is also involved in Encon Energy EOOD.
Fig. 3: Werner Diwald has been DWV chairman since 2014
Performing Energy was the first expert commission that the DWV initiated in 2015 on the back of Warner Diwald’s efforts; Diwald himself had previously created this alliance for wind-based hydrogen systems in 2011 and taken up the position of its speaker (see HZwei, January 2012). Participating organizations include Enertrag and Vattenfall as well as other companies which are also involved in other groups within the network.
Werner Diwald addressed the situation regarding some association members by stating in an email seen by H2-international: “The media’s assumptions about a possible breach by the DWV of compliance rules in relation to the funding application made by the HyMobility innovation cluster are unfounded. […] There was no improper influence exerted by the DWV. The DWV does not accept funding to carry out its statutory activities. […] By virtue of the funding of the HyMobility innovation cluster by the BMDV, the DWV has clearly not placed itself in a position of dependence on the government.”
Furthermore, the DWV has yet to issue a public statement, with the exception of a communication disseminated to association members (as seen by H2-international). The message sent, at the end of February 2024, outlined that “initial measures” have been “immediately introduced” that “go beyond the content of the DWV’s ‘Code of Compliance’ in order to make a comprehensive review of the situation.” It goes on to say that the DWV executive committee has “immediately commissioned a comprehensive review of the DWV’s compliance rules and of external and internal processes and procedures in the context of funding applications and funding allocations.” This is to be carried out by Berlin law office Redeker Sellner Dahs.
H2 funding frozen?
The saga then reached its peak after Der Spiegel reported that the transportation minister had allegedly frozen all funding for H2 projects. According to the article, no more funding is to be approved for the sector for the time being and no further agreements are to be concluded. Even amendment notices will require approval at state secretary level, it said.
However, a press spokeswoman for the ministry clarified the issue at a press conference on Feb. 21, 2024, by stating that the ministry had “not stopped hydrogen funding per se” but is carrying out more thorough assessments of funding applications. These “are currently focused on the approvals procedure for the DWV’s HyMobility funding project.” Should relevant evidence be produced during the investigation, further funding projects will also be examined more closely if necessary.
The reason for this tightened approach seems to be the Brunner affair. It relates, among other things, to the email exchange that took place via a personal GMX account through which Klaus Bonhoff and others communicated with Bavarian businessman Tobias Brunner, managing director of Cryomotive and Hynergy and a key figure in establishing the hydrogen technology application center WTAZ in Pfeffenhausen. LobbyControl disapproves of this “use of a private email account for official communication” since it meant this email exchange was not known to the ministry’s internal review department and therefore could not be taken into consideration in its final report. In all, there are 14 gigabytes of data that require sifting, which explains why there is a delay in the processing of further approvals.
Year 2022 saw fuel cell shipments creep up over 2021 numbers, though the latter was a remarkable year. When 2021 exceeded 2020’s MW numbers by over 70%, we thought we were finally seeing the uptick that had been anticipated – the classic “hockey stick” pattern. But the structure of the industry – and its reliance on only a few players for the majority of shipments – means that growth comes in spurts.
E4tech’s eighth annual Fuel Cell Industry Review showed just under 86,000 units shipped in 2021, or just over 2,300 MW, even with the COVID pandemic still hanging over markets. But this rapid growth was largely due to the activities of two vehicle OEMs, Hyundai and Toyota, together accounting for over 70% of the megawatts. But even after taking these out of the picture, growth continues – slowly but surely.
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E4tech is now part of ERM and the team is continuing to research and write the Review. The ninth FCIR shows that 2022 shipments were similar to the year before – with the continued but slow growth still led by Hyundai and Toyota, at over 60% of MW shipments, and by fuel cell buses and trucks into China. In 2022, we estimate nearly 89,200 fuel cells to have been shipped, amounting to almost 2,500 MW.
Analysis by region
For vehicles (which by far is the largest contribution, at 85% of all shipments by megawatts), much of the demand was localized to China and South Korea. China saw over 4,150 units being shipped, across all modes of mobility (including forklifts, now slowly taking off in the country), while South Korea saw nearly 10,400 deployments, dominated by Hyundai’s Nexo. Together with 831 Toyota Mirais going into the home market of Japan, Asia now accounts for around 15,600 units into transportation markets, or 17% of global shipments of fuel cells by number, but rather more impressively some 1,500 MW (60%) of the shipped megawatt count.
Hyundai is benefitting from the 50% subsidy for fuel cell vehicles in South Korea. South Korea is now also the single largest market for large stationary units, in CHP and prime power modes. Stationary shipments into the country grew from 147 MW in 2021 to 196 MW in 2022 (8% of the global MW count). These numbers illustrate the importance of South Korea for fuel cell shipments – and, moreover, the key role of sustained policy and subsidies in helping fuel cell companies and OEMs to achieve volume.
In context of the Japan’s Ene-Farm program, across all markets (stationary, mobility and portable), Asia accounts for 60,850 units (two-thirds of global shipments) and 1,770 MW (71% of global shipments). Behind Asia is North America, with around 14,550 fuel cell shipments (nearly 485 MW, or 19% of global shipments in megawatts), led by Toyota and Bloom Energy shipments to the United States. Europe accounted for roughly 13,250 of fuel cell shipments in 2022, down from just over 14,000 units in 2021. The fall in unit shipments followed the completion of the PACE program of the US Inflation Reduction Act and the imminent closure of KfW-433 grant funding by Germany. In megawatts, the count slightly increased, from a corrected 204 MW in 2021 to 228 MW in 2022, about 9% of the global market. Fuel cell vehicle shipments to Europe are lower than for Asia and the US because of the low subsidies provided by the national governments.
Analysis by application
Fuel cells for mobility, primarily cars, continued to dominate the overall count. Across all modes of mobility (including forklifts), 85% of shipments (2,100 MW) fell into this category in 2022, 150 MW more than in 2021. In units, mobility accounted for 35% of shipments in 2022, a slight fall from 2021’s share. So, the message is transportation is growing, but other fuel cell markets are growing too.
The next main contributor to vehicle shipments is China, with a record 3,789 units (buses and trucks) being shipped over 2022. Together, these are estimated as contributing 387 MW to the overall count in 2022.
While nearly 1,000 fuel cell buses were shipped into China in 2022, fewer came to Europe in 2022 (only 99 registrations). According to CALSTART figures, as many as 82 new fuel cell buses were fielded in the US in 2022, mostly in California. Outside China, fuel cell truck shipments globally in 2022 remained minuscule. This could change, given the business plans of Cellcentric, Plastic Omnium, Hyzon and others.
Fuel cells for ships and for aviation remains exploratory, now with a growing emphasis on propulsion rather than hotel loads or auxiliary power. Forklifts continue to be a major application for fuel cells, albeit with fewer unit shipments in 2022 (over 9,650 units) compared to 2021 (over 13,400 units). Prime power and CHP comprise a large part of the remaining demand, in unit numbers and in MW. By number, micro-CHP still dominates, with Japan leading with its Ene-Farm program. ACE shows 42,877 units being installed in 2022, over 3,000 units more than the previous year. Outside Japan and Europe, micro-CHP shipped in negligible numbers, further demonstrating the criticality of country-to-country policy in supporting fuel cells. Together, prime power and CHP across the power range contributed 364 MW shipments in 2022, up from 335 MW in 2021. Although a growing emphasis for developers, fuel cells for grid support and off-grid power has remained subdued, at 14 MW (for both years). Shipments of portable fuel cells (including smaller ported APUs, less than 20 kW in power output) showed an increase, from just over 6,000 units in 2021 to nearly 8,000 units in 2022. These are supplied globally, but most feed into European and North American industrial and consumer markets.
Shipments by fuel cell type
PEM continues to outweigh other fuel cell types in shipments, both in volume and in MW capacity. Of the nearly 90,500 fuel cells shipped in 2022, over 55,000 were PEM. By megawatts, PEM fuel cells recorded 2,151 MW, 86% of the overall volume of shipments.
High-temperature PEM, generally utilizing methanol rather than hydrogen as a fuel, continues to grow, led by Advent Technologies. While still a fraction of overall PEM units at present, shipments are set to grow more aggressively given the improved logistics and increased runtimes enabled by the methanol fuel. DMFC (direct methanol) had a good year, with nearly 8,000 units shipped over 2022, mostly from SFC Energy.
SOFC (solid oxide) grew to nearly 27,000 units in 2022 (mostly micro-CHP, by number). The MW count grew from 207 MW in 2021 to 249 MW in 2022. Much of this is attributable to stronger sales from Bloom Energy. PAFC (phosphoric acid fuel cell) shipments fell, and while no new MCFC (molten carbonate) system placements were recorded over 2022, FuelCell Energy continues to produce significant volumes of stacks, for mid-life refurbishment of systems. AFC (alkaline) shipments increased to over 100 units in 2022, way down on other fuel cell types despite the lower cost potential, both for the fuel cell stack and the hydrogen purity requirement.
Summary
Fuel cells had a good year in 2022. Despite shipments being dominated by a few key suppliers into just a few countries, we are at last beginning to see shipments into Australia and South America, buoyed by the greater interest in hydrogen generally. And while interest is helpful, it remains the case that fuel cells have yet to break through the high capital cost threshold, and (for the hydrogen-fueled units) high fuel prices. We are slowly seeing this happen, through big changes to the supplier landscape, the IPCEI initiative in Europe, significant capacity upgrades to fuel cell production, and the Inflation Reduction Act in the US. But for now, the message remains the same: sustained support from governments is still needed to allow fuel cells to fully support the energy transition. Some fuel cell companies are now also purposing their designs to electrolysis, to help push the market, and with it the hockey stick.
ERM’s Review, a digest of the year’s activity, together with an analysis of fuel cell shipments by region, type and application year on year, is available at http://FuelCellIndustryReview.com. The 2022 edition is delayed, but coming soon. We would like to thank all the fuel cell shippers who graciously provide shipment numbers to us each year, which helps underpin our review.
Wind, sun and loads of expertise – these ingredients are to be used intensively in Oman to produce green hydrogen in the future. In contrast to other Gulf states, the Sultanate is making great strides in this regard. The green hydrogen is to be exported, but also used locally. First projects are underway and the infrastructure is being expanded. Experts see Oman as a promising partner for the clean energy transition in Germany.
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The excavators have rolled in; the sand has been swept out of improvised offices. The go-ahead has been given for a steelworks in the industrial port of Duqm in the Gulf state of Oman. Starting 2027, green hydrogen is to be produced here. “Vulcan Green Steel” is what the Indian owners from the family Jindal have named this business branch, for which a separate quay will be built to ship the products – directly opposite the other quays, from which containers and vehicles are transported across the Arabian Gulf. Customers for the green steel Jindal sees in Europe, for example in the German automotive industry.
The infrastructure in Duqm (see photo on p. 4) is growing rapidly, and the new steel plant is one of the building blocks of Oman’s future, which is to logically develop in the direction of green hydrogen. For the export, according to Dr. Firas Al-Abduwani of Oman’s energy ministry, ammonia and methanol are currently being considered as the main means of transport. Part of the new energy source, however, they want to use within the country. Other parts and products such as green steel are to be shipped via the industrial ports in Sohar, Duqm or Salalah in southern Oman, for example to Germany.
Future plans with the best prerequisites
Experts from the International Energy Agency (IEA) and the German foundation Stiftung Wissenschaft und Politik (SWP, see info box) see ideal conditions for the future plans of Oman: more than 2,000 kilometers of coastline, along which the wind blows around the clock, and eight to more than ten hours of sunshine per day.
Furthermore, the country has leading expertise in hydrogen production, well-developed ports with strategic positions and plants for desalinating seawater. These usually work with reverse osmosis to filter out dissolved substances. The associated costs for hydrogen production Dr. Dawud Ansari from the research group Globale Fragen (global questions) of SWP estimates as very little – he talks of about one percent of the cost per kilogram hydrogen.
The state institution Hydrom, however, does not want to commit itself to this yet. Hydrom has been developing a master plan for the green hydrogen sector in Oman since autumn 2022 and is creating the conditions for production. Also currently being discussed is the use of treated wastewater from the oil and gas industry.
Oman is pressing ahead with the development of green hydrogen as a future energy supplier so that it will be economically no longer predominantly dependent on dwindling oil and gas reserves. Also to be supported will be the country’s climate neutrality plans that the ruling sultan Haitham Bin Tarik set out in Oman Vision 2040. This could make the Sultanate a promising candidate for supporting the energy transition in Germany.
According to the Wuppertal Institut, a think tank for sustainability research, only up to one sixth of the expected H2 demand in Germany can be covered by domestic production in 2030. The majority will have to be imported – partners for this are being sought worldwide.
Pioneering work begins with five local consortia
Against this background, Oman is bringing itself in position: The strategy of Hydrom would allow for Oman to produce one million metric tons of green hydrogen annually starting 2030, and by 2050, it is to be around 8.5 million tonnes. By then, Oman wants to have fully reduced its CO2 emissions and additionally to have created around 70,000 new job positions. Estimated investment cost according to Hydrom and the energy ministry: around 150 billion US dollars.
To achieve the ambitious goals, pioneering work is now required: For example, it is important to attract companies that develop the corresponding technology. Electrolyzers for industrial processes that use sun, wind and water must be built. Furthermore, plans for sustainable, effective and economical business models are still needed.
The first five international consortia have just been awarded contracts by Hydrom to produce green hydrogen and ammonia for export and domestic consumption on a total area of around 1,500 square kilometers (580 sq mi) in the region Duqm. A further 1,800 square kilometers of land are currently being made available in southern Oman, in Salalah, via a second public tender. This auction is running until April 2024.
Potential for German companies
German companies are already involved in development in Oman. But Oman’s high-flying plans offer much more potential. This is the view of, for example, Dr. Abdullah Al-Abri, Omani consultant at the IEA – and hopes that the cooperation that was agreed in a Joint Declaration of Interest with Germany in summer 2022 will gain momentum.
“So far, the potential customers for green hydrogen from Oman are still mainly located in Japan or Korea,” opined the expert. Dr. Ruth Prelicz, expert for hydrogen and renewable energy systems at the chamber of commerce AHK Oman, however, stressed: “In summer 2023, the German energy supply company SEFE (Securing Energy for Europe GmbH) concluded an offtake agreement for liquefied natural gas (LNG) from Oman. This contract for LNG deliveries serves to build trusting business relationships and is also seen as a precursor to later deliveries of green hydrogen.”
Alok Bisen, who works for the Indian steel company Jindal, showing the construction area for green steel production in Duqm
Ruth Prelicz is observing the development on site: She is supporting the hydrogen foreign office Wasserstoffdiplomatie des Auswärtigen Amtes (H2Diplo) and the energy dialogue of the German economy and climate protection ministry (BMWK) in Oman. The expert sees a number of opportunities for German companies to benefit from cooperation with Oman in the field of green hydrogen: “It’s not just about the acceptance of the end product. Oman is also interesting as a market for German high-tech technology. Siemens Energy and ThyssenKrupp are established as potential suppliers of electrolyzers in Oman. And in the area of hydrogen transport, the Bavarian hydrogen experts of Hydrogenious as well as MAN Energy Solutions have presented their technology in the field of liquid organic hydrogen carriers (LOHC) and methanol.”
Also companies specializing in hydrogen compressors, pipelines or measuring devices, in her view, will be in demand in the country in the future. Further opportunities for German companies could be in the areas of green hydrogen certification as well as training and education. According to the expert, TÜV Süd, for example, is already active in this in Oman.
Oman’s stable position in the region
That cooperation with the Sultanate is not only worthwhile from a trade policy perspective stressed Dr. Dawud Ansari of SWP. For him, closer (energy) relations with the Sultanate as Germany’s central partner in the region bring further advantages: “Germany has an interest in strengthening relations with and the economy in Oman, as the Sultanate constitutes a cornerstone of regional peace processes. Oman itself is very stable and safe – both in terms of trade relations and domestic policy and in relation to its neighbors. The Yemen conflict and other regional disputes will, thanks to Oman’s diplomatic fortitude and border security, not spread to the country.”
The research for this text was supported by Park Inn by Radisson Hotel & Residence Duqm as accommodation. https://www.radissonhotels.com
Further reading:
Current information from the state institution Hydrom, which is developing a master plan for the green hydrogen sector in Oman: hydrom.om
Vision 2024 of the Sultanate of Oman: oman2024.om
More information about the port in Duqm, where Oman’s first green hydrogen projects will appear:https://portofduqm.om
Stiftung Wissenschaft und Politik, Publikationen, Dawud Ansari: Wasserstoff aus Oman für Deutschland und die EU – nicht nur aus energiepolitischer Perspektive sinnvoll. SWP-Aktuell 2023/ 9.3.2023 https://www.swp-berlin.org/publikation/wasserstoff-aus-oman-fuer-deutschland-und-die-eu
The International Energy Agency (IEA), a cooperation platform in the field of research, development, market introduction and application of energy technologies, has commented on Oman’s great potential for the production of green hydrogen: https://www.iea.org, subitems News / Oman
The chamber of foreign trade Außenhandelskammer (AHK) Oman maintains a representative office of German industry in Oman’s capital Muscat. There, Sousann El-Faksch and Dr. Ruth Prelicz (ruth.prelicz@ahkoman.com) give information on the topic of green hydrogen:https://www.ahk.de/oman
Interview with Dr. Kai Fischer, Director at RWTH Aachen
The efficient scaling of green hydrogen production technologies is an essential step in making hydrogen an economically sound part of the energy transition. With regard to this necessary and massive capacity expansion, the plastics industry has a lot to offer as far as the hydrogen industry is concerned, because plastics are high-performance materials whose property profile can be engineered very precisely for the intended application. Additionally, the processing technologies in the plastics industry allow high-tech components to be produced efficiently and in large numbers. Dr. Kai Fischer, scientific director at the IKV and responsible for the topic hydrogen economy, explains in this H2-international interview why the exchange between the two industries is so important, what significance plastics have for the scaling of hydrogen technologies, and how the cooperation between the participating industry partners is to be continued in the “Hydrogen Business and Technology Forum”.
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H2-international:Following the hydrogen study produced in the past two years, there now is the “Hydrogen Business and Technology Forum” to intensify the exchange between the hydrogen industry and the plastics industry. Why is that now important?
Fischer: Hydrogen is intended to become the backbone of the energy turnaround. Today, approx. 96 % is obtained from fossil resources such as natural gas and coal. Only 4 % is produced by electrolysis. For this – as some people may remember from school – water is broken down into hydrogen and oxygen using electricity. Electrolysis is the way to produce “green”, i.e. climate-neutral, hydrogen. And even for this 4 % electrolysis, only a small proportion of renewable energy is currently being deployed. Consequently, only a very, very small part of the production capacity is at present suitable for producing green hydrogen. Yet all today’s projections are aimed at producing green hydrogen. It is indeed important to see that a great deal needs to be done here with completely new development work. Large numbers of electrolysers and the corresponding infrastructure have to be put in place. That again means working with large numbers, and large numbers are always predestined for plastics. For this reason, we believe that plastics are the enablers to make hydrogen production economically scalable.
And that is why you believe the plastics industry must get together with the hydrogen industry to exchange information and ideas?
Exactly. The people in the hydrogen industry are familiar with all the requirements of the process engineering plants, the media, the temperatures, the pressures etc. But, of course, they think not in plastic but in metal. It is not the case that the construction can simply be switched from metal to plastic. That would not bring any advantages. In order to find new solutions for the requirements of systems, it is necessary to go beyond substituting single metal components with single plastic components, and to look at functional integration. Precisely for this, this application know-how must be communicated so that the plastic value chain can say how solutions would ideally look in plastics.
Are there already examples in the hydrogen industry?
Yes of course. As an example, let us look at the end plates of a fuel cell. Here, many media have to be conveyed, both gaseous and liquid. Connections also have to be integrated. If they are made of metal, it means that a very large number of individual components have to be mounted. In the meantime, there are some applications in which this is solved by a single large injection-moulded part in which all media lines, connections, electronics etc. are already integrated.
This means that the hydrogen industry is not yet aware of the possibilities offered by the plastics industry?
These are two completely different worlds. The facilities for producing or converting hydrogen are classic process engineering plants. They consist predominantly of stainless steel with stainless steel pipes. The producers of such plants are indeed only seldom aware of the possibilities offered by plastics. For this reason it is important to bring the hydrogen OEMs with their knowledge of the requirements together with the plastics specialists with their know-how and their technical capabilities. Only in this way can we start to think in terms of highly integrated products that can be automatically manufactured in very, very large numbers. This is an absolute necessity if the scale-up of green hydrogen technologies is to succeed within a reasonable time and at reasonable cost.
How did the idea of a network forum come about?
The idea of a network forum came because, in 2021, we at IKV launched a market and technology study in cooperation with more than 20 companies in order to deal with this issue holistically. The study is, however, only really the basic package. Our aim was always to operate a continuous exchange to identify how plastics can help in establishing hydrogen. For this, we need continuity, and we have now implemented this in the form of this forum, which will meet regularly twice a year. These meetings will be supplemented by continuous technology monitoring. At the kick-off meeting, we also decided that there would be individual workshops on special topics between the meetings.
What were your impressions of the kick-off meeting and what did you think of the content?
It was a great event! We had a total of 50 participants in the room and four keynote presentations that were divided in equal parts between users of hydrogen systems and solution providers from the plastics value chain. We had very open and transparent discussions. In the breaks, the business cards were flying around and everyone was networking on a grand scale. As part of the event, we also charted the course for defining, according to the requirements, the elements of further cooperation for these two target groups.
As far as the content was concerned, I felt that a very lively demand exists for understanding the systems in the various segments – especially on the part of the plastics industry. I also felt that there are many companies who, irrespective of the competition in their hydrogen systems, are prepared to talk about the challenges because they hope for the push of the open-innovation approach – in other words the push from the supplier industry – and want to create competitive advantages through this in future.
Another aspect that I took from the meeting is that the companies in the plastics value chain, some of which are competing with each other, are very open to cooperation. For example, we discussed the fact that we would sound out in the consortium which testing and characterisation processes are available in which companies so that the companies can supplement each other. In this way, it will also be possible to identify supplementary demands and derive measures to realise them. It was truly noticeable that everyone is keen on baking this large pie together instead of generating competition and trying to grab the biggest slice of a small pie. This seemed to me to reflect the spirit of the meeting generally.
As you said at the beginning, the market and technology study forms the basis for this network. What are the most important things you have taken from this?
The hydrogen industry is still driven very much by traditional process engineering plants. An important finding is, however that we do not have to revolutionise the plastics industry in order to offer solutions to the hydrogen industry. Plastics can be compatible and there are numerous applications and good examples for the implementation of highly integrated and function-integrated components. This means that if the scale-up is necessary and the number of pieces must increase, the plastics industry can offer these solutions without reinventing the world. It is possible to transfer a lot from other industries, but it is naturally not necessary to be familiar with the specific applications in order to be able to suggest suitable solutions for the hydrogen industry. The good news is that we do not now have ten years of development ahead of us and the plastics industry must not fundamentally change or develop completely new products. For each industry it can take what is already there in order to further develop it and transfer it.
What happens now?
Our Forum member Freudenberg held theme workshop in August in addition to our half-yearly meetings to discuss the questions that the Forum participants had addressed fairly openly at the kick-off. The idea for specific workshops was born during the kick-off because the participants deisred an exchange on how to bring plastics expertise specifically into the development of new systems. Furthermore, the team is now starting the Market & Technology Monitor in order to continuously observe the market. We have agreed that it should be more than simply collecting the available information. The information should be questioned, evaluated and categorised. We will look exactly how reliable it is and how realistic the implementation scenarios are. In this way we will draw up an organised list of information, that we will pass on at three-month intervals to the partners in the forum.
Is it still possible to join?
Yes, it is. We naturally want this network to grow, and are pleased to have both small and large companies from the plastics value chain and naturally companies from the hydrogen value chain. Through the synergies of both industries, we can master a scale-up for green hydrogen and make it economical.
Hydrogen Business and Technology Forum
Dr. Kai Fischer leads the „Hydrogen Business and Technology Forum“
With its “Hydrogen Business and Technology Forum”, the Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University has established a close network between the hydrogen economy and the plastics industry, where it regularly fosters the connection of requirements and application know-how with material and production know-how.
The “Hydrogen Business and Technology Forum” emerged from a market and technology study on plastics in the hydrogen economy initiated by the IKV and completed in November 2022. About 20 industry partners were already involved in the study. With regular workshops and a continuous Market & Technology Monitoring, the work is now being continued in the “Hydrogen Business and Technology Forum”. The kick-off for the Forum was 16 May 2023. The first thematic workshop dealt with “Testing and Analysis of Plastics in Hydrogen Applications” and took place on 9 August 2023 and was hosted by the Forum member Freudenberg. On 19 October 2023 Forum members met again at the IKV for its second regular Workshop. The Forum is still open to new members. Information at H2@ikv.rwth-aachen.de
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