• Has anyone built a 500kW PEM Stack yet?

    Posted by Steven Oji on October 11, 2022 at 06:56

    There seems to be an upper limit or “glass ceiling” in the size of PEM fuel cell stacks available, and it would be interesting if anyone has realized a system as big as 500kW in one stack. So not a combination of 5 100kW stacks, but one 500kW stack in one.

    Roger Penn replied 1 year, 7 months ago 4 Members · 3 Replies
  • 3 Replies
  • Ganapathy Iyer

    October 12, 2022 at 03:23

    Horizon (https://www.horizonfuelcell.com) seems to have build the “World Record 500hp Fuel Cell Stack (370kW), The most powerful single module PEM fuel cell in the world”

    Consider a 500kW FC. The stack current (500 amps) limits the cell area to around 250 cm2 and the voltage at 1000V. At 1000V, and 0.6V/cell it would mean 1667 Cells.

    At 3mm per cell this is 5 meters. The Stack would be a 250 cm2 x 5 meters which is a very disproportionate shape.

    If we were to increase the current (> 500 Amps) larger stacks could be achieved. Since FC’s are used for multiple applications, standardizing sizes and modularity is a better approach.

  • Hermann Huber

    October 13, 2022 at 16:47

    A 500kW cell should then cost around US$ 4,000,000?! After around 30,000 hours of operation, more than 1,600 cells have gone. I’m looking for the economy!

  • Roger Penn

    November 18, 2022 at 18:32

    One of the biggest stacks I have seen (both large active area and high number of cells) was for stationary power. In link below you can see a person standing next to the large stack. It was for a 250 kW application, but could have been run to higher current density (was also an older technology). Had 4 cell rows connected in series (would have trouble keeping a single row compressed).


    For stationary applications can envision a single 500 kW stack, but what is the size of the market to warrant designing such a stack? It seems that SOFC is better suited for stationary applications than PEM.

Log in to reply.