Hydrogen is considered one of the key energy carriers in the effort to transform industry and transportation sectors to be climate-neutral. According to the German government's National Hydrogen Strategy, ten gigawatts of electrolysis capacity are expected to be built in Germany alone by 2030. This would meet one-third to one-half of the domestic demand and require an almost unprecedented scaling of current capacities. While many view this plan as completely unrealistic, enomyc author Wolfram Hackbarth sees opportunities. The industrial production of the stacks required for this is highly complex, but thanks to digitalization and Industry 4.0, it can still be economically viable—even in high-wage countries.
Stacks are the heart of an electrolyzer and play a crucial role in hydrogen production. Technically, stacks consist of multiple electrolyzer cells connected in series. Each cell contains two electrodes—an anode and a cathode—as well as an electrolyte that conducts ions. When the electrolyzer operates, electrical current is passed through the stack, splitting water (H₂O) into its components: hydrogen (H₂) and oxygen (O₂). Hydrogen is released at the cathode, while oxygen is generated at the anode. Stacks are vital for expanding hydrogen production because they determine both the efficiency and capacity of electrolyzers. Thanks to their modular design, production capacity can be easily increased by adding more cells. Stacks must also be extremely durable and efficient to produce hydrogen on a large scale with minimal energy losses. The industrialization of stacks for hydrogen-producing electrolyzers is a highly complex process that involves automation, Industry 4.0 technologies (I4.0), and cross-departmental collaboration. However, digitalization and Industry 4.0 are unlocking new potential, making it possible to produce these critical components economically and sustainably, even in high-wage countries. The primary goal is to make production as efficient, automated, and flexible as possible, reducing costs—a key factor for ensuring that production facilities in Western Europe remain competitive in the long term. Considering these trends, the industrialization process can be described as follows.
Requirements and Specifications Document: Incorporating Automation
Even during the creation of the requirements document, where the development department defines the technical specifications, future automation potential and the integration of Industry 4.0 technologies should be considered. Meanwhile, the industrial engineering team ensures that the product design supports future automation processes.
- Modular Product Design: A modular design of the stacks allows for flexible adaptation of production processes to various requirements. This is crucial for leveraging future automation potential and quickly responding to new technologies.
- Scalability of Production: The requirements document should specify from the outset that production processes are designed to be scalable, allowing for easy adjustments to increasing or even temporarily decreasing production volumes based on customer orders.
- Interfaces for Industry 4.0: Production systems must be designed from the beginning to be compatible with I4.0 technologies such as smart sensors, connected machines, and data analytics platforms. This ensures that the production line can keep pace with advancements in digitalization.
The specifications document elaborates on these requirements and outlines the technical details of the automation approaches. It also defines the integration of handling robots, for example, which ensure ergonomic and efficient management of heavy components.
Connected Production with Industry 4.0 and Smart Factory
The implementation of Industry 4.0 in the production process is a key component for the cost-effective manufacturing of stacks in high-wage countries. Through a connected production environment, also known as a Smart Factory, machines and processes can be monitored and optimized in real time. Some interesting approaches include:
- Linking Machines and Data: By networking machines, robots, and sensors, all production data can be captured and analyzed in real time. This enables continuous optimization of the production process and a rapid response to disruptions or quality deviations.
- Predictive Maintenance: Sensors in machines and robots continuously monitor the condition of the equipment. This allows for early detection of maintenance needs and helps avoid unplanned downtime. As a result, equipment availability increases, and production costs decrease.
- Self-Learning Production Systems: Through machine learning and artificial intelligence, production systems can continuously analyze data and autonomously optimize processes. For example, systems can determine the optimal timing for robot movements or the most efficient production route. They can also autonomously interrupt series processes in production and logistics if deviations from specifications are detected, such as in quality rates or process times.
In the collaboration between industrial engineering and production, this networking is realized through detailed planning and integration of machines and IT systems in daily operations. This "smart" production environment enables significant efficiency gains, leading to cost-effective production of stacks in high-wage countries in Western Europe.
Automation as the Key to Efficiency
Another essential lever in the industrialization concept is automation solutions, which are particularly crucial in high-wage countries. The use of robotic technologies and collaborative robots (cobots) in production helps reduce labor costs while simultaneously increasing efficiency:
- Handling Robots: These can take over heavy physical tasks by lifting, positioning, and precisely assembling components that weigh over 50 kilograms. Utilizing industrial robots significantly reduces the physical strain on employees while increasing production speed.
- Collaborative Robots (Cobots): Unlike traditional industrial robots, cobots work directly alongside humans. They handle supportive tasks, allowing people to focus on more complex responsibilities. These robots are versatile and can be deployed across various production areas due to their high adaptability.
- Flexible Automation: Automation solutions must be designed to be flexible to respond to different product variants and changes in demand. This means that robots and machines can be quickly reprogrammed or retooled to take on various tasks.
In close collaboration among development, industrial engineering, and production, the requirements for automation are planned, implemented, and continuously optimized.
Economic Manufacturing in High-Wage Countries: Sustainability and Efficiency
For stacks used in electrolyzers to be produced economically and sustainably in Western Europe, several conditions must be met.
Firstly, a clear automation strategy is essential for reducing labor costs. By increasing the use of robots and automation, the proportion of labor costs in overall production can be significantly lowered. Secondly, intelligent production systems must be employed to ensure optimal use of resources such as energy, materials, and labor time. Such resource-efficient production is not only cost-effective but also reduces the ecological footprint. A third requirement is the systematic utilization of local value chains. Regional production minimizes transportation costs and reduces supply chain risks. This will be a crucial competitive advantage, especially during times of global uncertainty, enabling sustainable manufacturing operations in Western Europe.
Finally, high-wage countries have another asset up their sleeve: they typically possess a sufficient number of highly skilled professionals. Targeted training programs that teach employees how to work with modern technologies like robotics, automation, and data analysis can effectively harness the potential of this workforce.
The long-term maintenance of competitiveness in high-wage countries will largely depend on a smart combination of automation, resource efficiency, and a qualified workforce. In this context, development, industrial engineering, and production collaborate closely to align technological requirements with economic realities.
Future Trends in the Production of Electrolyzers
In addition to current technologies, several forward-looking trends are expected to have a lasting impact on the industrialization of electrolyzers.
One significant trend is the potential use of additive manufacturing (3D printing) for some components of the stacks in the future. This approach would not only allow for material savings but also increase the flexibility and customization of production. Additionally, a digital twin of the production line can be utilized to virtually simulate and optimize processes. This way, potential bottlenecks can be identified and addressed early, before they impact production. Last but not least, artificial intelligence (AI) and big data are likely to play a significant role soon. The use of AI and big data will enable the analysis of vast amounts of data from the production process, contributing to a continuous increase in production efficiency. Predictive analytics can also forecast production workflows and facilitate ongoing improvements.
Automation and I4.0 Ensure Future-Proof Stack Production – Even Here
The industrialization of stacks for electrolyzers used in hydrogen production requires a holistic approach that considers both current technological developments and future trends. Close collaboration between development, industrial engineering, and production is essential to create future-proof and economically viable production processes. By strategically utilizing automation and Industry 4.0 technologies, production can remain competitive and sustainable, even in high-wage countries. The integration of smart production systems and the use of robots are key strategies for reducing costs, increasing efficiency, and alleviating the burden on employees.
