Electrolysis Laboratory

In our 700 m² electrolysis laboratory, we conduct research into innovative technologies for the development and optimization of high-performance materials and components for water electrolysis with proton exchange membranes (PEM) and anion exchange membranes (AEM). We develop novel cell and stack designs, carry out short-term electrochemical measurements with our customized test benches, and analyze the material properties of the components using various ex-situ measurement methods. To understand aging mechanisms and to derive rapid aging tests, we examine the durability of the cell components using automatic long-term measurements.

In production research, we concentrate on manufacturing processes for membrane electrode assemblies (MEA). We optimize manufacturing processes from catalyst powders to MEA and support our customers in implementing industrial solutions for series production.

By monitoring our customers’ electrolyzers, we round off our range of services with the development of operational management concepts, including measurements for condition-based maintenance approaches.

Our services are aimed at companies and research institutions that develop and manufacture components and systems for hydrogen production.

Our interdisciplinary team has many years of experience in the development and characterization of materials and components for electrolysis and in the engineering of electrolysis test benches and systems.

Our Services and Equipment in this Lab Include:

• Material and component screenings
• In-situ characterization of electrolysis cells and stacks
• Ex-situ measurements of components for electrolysis
• Monitoring of electrolysis systems

We also offer the following services:

• Production research and manufacturing processes for membrane electrode assemblies
• Process simulation of hydrogen systems

We have various laboratory cells developed in-house for the electrochemical characterization of materials and components for water electrolysis.

60 cm² Along-the-Channel Test Cell

• for detailed, spatially resolved measurements of current density, temperature, and electrochemical impedance up to 80 °C and 15 bar (g).
• with 10 segments and 3 reference electrodes at the inlet, in the middle, and at the outlet of the flow field

25 cm² Test Cell

• for pressure measurements up to 80 °C and 30 bar (g)
• with reference electrodes on the anode and cathode 

4 cm² Test Cell

• for standard measurements up to 80 °C and 6 bar (g)
• with or without electric heating 

The contact pressure can be adjusted over a wide range for the 25 and 4 cm² cells, and the pocket depth can be varied for various thicknesses and PTL layer structures. On customer request, we adapt our proprietary test cells to different materials and components.

We use individually configurable and flexible test systems that can run various measurement protocols fully automatically to address the diverse issues faced by our customers and partners.

Cell Testers for Lab Cells

• power electronics: 0 to 1,000 A / 0 to 5 V
• temperature: 20 to 120 °C
• pressure: 1 to 50 bar (g)
• for electrolysis cells with conventional active surfaces (4 cm² and 25 cm²)
• electrochemical impedance spectroscopy (EIS) and cyclic voltammetry (CV)

Stack Tester for Electrolysis Stacks up to Ten Cells

• power electronics:  
  • 0 to 1,500 A / 0 to 25 V
  • alternatively, 0 to 510 A / 0 to 80 V
• temperature: 20 to 80 °C
• pressure: 1 to 50 bar (g)

LabView Control

• unattended continuous 24/7 operation
• programming of individual measurement protocols using Python scripts

Our test systems operate in differential and equal pressure mode. The internal water treatment ensures that the conductivity of the electrolysis water is less than 0.1 µS/cm.

In addition to our test systems for electrochemical characterization, we have a wide range of additional ex-situ analysis equipment that can be used to determine various physical and chemical parameters and characteristics of materials and components for water electrolysis.

Measurement of in-Plane two-Phase Flow

For the determination of:

• pressure loss as a function of the flow rate
• water-gas ratio
• permeability, inertial resistance
• bubble characteristics and flow patterns

Either a single-phase (water only) or a two-phase (water with additional gas through porous material) flow rate can be set, both temperature-controlled and pressurized.

High-Precision Force-Displacement Measurement

For the measurement of:

• pressure-dependent sample height
• pressure-dependent elastic and plastic deformation rate
• pressure-dependent electrical resistance
• area-specific resistance (ASR) and interfacial contact resistance (ICR)

The measurement can be performed with single-layer samples and with multi-layer samples.

Pressure Tester

• for leak tightness and gas permeation measurements of test cells and stacks up to 70 bar (g)
• with Thermobox and temperature-controlled water bath

Gas Analysis

• for the measurement of foreign gas concentrations H₂ in O₂ and O₂ in H₂

Thermographic System

• for the detection of membrane defects

 ESEM/EDX and NAP-XPS 

(Environmental Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy and High Temperature and Near Ambient Pressure X-ray Photoelectron Spectroscopy)

• surface analyses

ICP-MS 

(Inductively Coupled Plasma Mass Spectroscopy)

• analysis of contamination and corrosion products from electrolysis operation

We offer scientific based monitoring in real-time of electrolysis systems, including condition monitoring and determination of key performance indicators (KPI). Our specially developed IoT (Internet of Things) system allows us to record a large number of system and stack parameters in high time resolution, evaluate them in detail, and thus optimize operational management concepts. This makes it possible to identify the degradation of components or problems in operation at an early stage, take proactive measures to compensate for them, avoid consequential damage, optimize processes, and thus reduce downtimes and costs of the electrolyzer.

Laboratory Equipment:

• PEM electrolysis system as flexible test platform
• IoT-based monitoring box
• gas analysis

Development and Evaluation of Hydrogen Infrastructures and Electrolyzers