Automized manufacturing of pressurized alkaline electrolyser

ongoing

The project aims to build an automated manufacturing facility for a new, innovative, alkaline pressurised electrolyser (PE). The facility will combine advanced technology, modern production techniques, and economies of scale to achieve the highest production volumes at a low cost. The aim is to reduce the levelised cost of hydrogen and make renewable energy more accessible and viable for widespread adoption. By replacing fossil fuels with zero-emission electricity and water to produce hydrogen, PE electrolysers will avoid all greenhouse gas (GHG) emissions relative to the reference scenario of production using fossil fuels. Calluna presents a first-of-a-kind commercialisation of a newly designed pressurised electrolyser that is more efficient, compact and less resource-intensive. The PE electrolyser is a modular product with a 25-megawatt (MW) capacity that delivers pressurised hydrogen gas. It is responsive, reliable, simple to install, and designed for an outdoor setup. It maintains high energy efficiency regardless of operational load, making it well-suited for intermittent renewable energy production. Each prefabricated module can be easily duplicated and combined for scalability. The plant will use modern production techniques and best practices from Nel’s fully automated electrode facility and other mass-producing industries. The electrolysers will reduce absolute CO2 emissions by 33.5 million tonnes over its first ten years of operation by using green electricity instead of fossil fuels to produce hydrogen. This is the equivalent of about eight million gasoline-powered passenger vehicles. Furthermore, being only a fraction of the size of a conventional alkaline electrolyser system, the total amount of steel required to make the electrolyser is reduced, saving an additional 500 thousand tonnes of CO2 throughout the project’s lifetime. Calluna will support the fulfilment of the European Green Deal by manufacturing innovative, clean tech components for hydrogen production. It will play a key role in meeting Fit for 55’s goal of reducing GHG emissions by 55% by 2030 and upscaling the European electrolyser manufacturing capacity in line with the Net-Zero Industry Act. The project will also contribute to the resilience of the European economy by reducing dependence on fossil fuels and increasing the use of renewable energy, thus supporting the implementation of the REPowerEU plan. The project will create jobs and stimulate economic growth in the region, contributing to developing business clusters and value chains and adding value to the local economy, creating 400 jobs within the company. It will also positively impact indirect jobs within suppliers and development partners along the hydrogen value chain while reinforcing research collaboration with universities and academia. The plant’s design and automation features will enable it to be easily replicated and scaled up to meet future European demand, helping showcase Europe as a leader in clean tech manufacturing and the hydrogen industry.