Ecolab – Ultrapure Water Solutions Optimizing Green Hydrogen Production

Ecolab – Ultrapure Water Solutions Optimizing Green Hydrogen Production

In green hydrogen production, ultrapure water (UPW) is critical for ensuring electrolyzer efficiency and longevity. Ecolab’s UltraClean™ ion exchange resins are specifically engineered to meet the strictest feedwater standards, enabling sustainable, high-yield, and cost-efficient hydrogen generation.

Water electrolysis for hydrogen requires feedwater with a resistivity of > 18 MΩ-cm (≤ 0.056 µS/cm) and a total organic carbon (TOC) content of < 1 ppb. When these standards are not met, ionic impurities such as Ca²⁺, Mg²⁺, Na⁺, Cl⁻, SO₄²⁻, and silica can cause fouling, electrode corrosion, and efficiency losses of up to 10%. With UltraClean™, these contaminants are virtually eliminated, allowing the electrolyzer to operate smoothly and improving hydrogen yield by 5–8%. For a plant producing 1,000 kg of hydrogen per day, this translates to an additional 50–80 kg/day, or approximately 1.8–3 tons annually.

Electrolyzer lifetime is also significantly extended. UltraClean™ resins protect membranes and electrodes from corrosion, leading to a 30–50% increase in service life and fewer maintenance interventions. Given that MW-scale electrolyzer replacements can cost $0.5–1 million, this represents substantial savings. Additionally, UltraClean™ resins have rinse-in times reduced from 20–24 hours to 6–8 hours, saving 30–50% of rinse water and minimizing downtime by 1–2 days, reducing overall OPEX by 5–10%.

UltraClean™ is compatible with all electrolysis technologies – PEM, AEM, and AEL. For PEM systems, the UltraClean UCW1899 resin specifically targets fluoride and PFAS fragments in the recirculation loop, preventing corrosion and lowering wastewater treatment costs. The product line includes single-use mixed bed resins (UCW1008), regenerable mixed bed resins (UCW1008R), and strong base anion resins (UCW1899), offering flexibility for various operational needs.

Beyond products, Ecolab delivers comprehensive technical support through PuroPASS™ (on-site evaluation and optimization of water treatment systems) and PRSM™, a web-based resin system modeling tool that simulates plant performance under different operating conditions. With global manufacturing capabilities, one of the largest technically trained teams in the ion exchange industry, and over a century of innovation, Ecolab is a strategic partner enabling green hydrogen projects to lower costs, increase yields, and extend electrolyzer life.

Ecolab’s Strengths in Green Hydrogen Production (Qualitative Overview)

UltraClean™ Resin Technology – Ultrapure Water (UPW)

• Supplies ultrapure water with resistivity > 18 MΩ-cm and TOC < 1 ppb, meeting the stringent requirements for water electrolysis.

• Reduces resin rinse time, minimizing system downtime and wastewater volume.

Extended Electrolyzer Life

• Ion exchange resins protect electrolyzers from contaminants and corrosive by-products, reducing maintenance frequency and enhancing durability.

Optimized Hydrogen Production Efficiency

• High-quality UPW ensures stable electrolysis processes, increasing hydrogen yield and overall production efficiency.

Reduced Operational Costs

• Purolite UltraClean resins provide high contaminant removal capacity, lowering wastewater volume and treatment costs.

• Extended component lifespan reduces replacement expenses and operational downtime.

Compatibility with All Electrolysis Technologies

• PEM Electrolysis: Strictly controls Ca, Mg, Na, Cl, SO₄, silica, and metals; removes fluoride and TOC to prevent corrosion and efficiency loss.

• AEM Electrolysis: Maintains low conductivity, reducing silica, iron, Ca, Mg, and TOC to protect electrodes.

• AEL Electrolysis: Removes TDS, Ca, Mg, Na, and Cl from NaOH/KOH electrolyte solutions to prevent side reactions and optimize hydrogen generation.

Comprehensive and Specialized Product Portfolio

• UltraClean UCW1008: Single-use mixed bed resin for ultrapure polishing.

• UltraClean UCW1008R: Regenerable mixed bed resin for cost efficiency.

• UltraClean UCW1899: Strong base anion resin for water loop protection against fluoride, sulfate, and PFAS, minimizing wastewater treatment issues.

Solutions Beyond Products

• Technical Support and Consulting: One of the largest expert teams in resin technologies.

• PuroPASS™: On-site assessment and optimization service for softening and demineralization systems to improve efficiency and service cycles.

• Purolite Resin System Modeling (PRSM™): Free online simulation tool calculating hundreds of variables for instant performance evaluation.

• Global Manufacturing Capabilities: Advanced technology, strict quality standards, and global production to meet diverse, demanding customer needs.

Summary

Ecolab delivers a comprehensive solution—including UltraClean™ materials, optimization tools, and technical expertise—that enables the green hydrogen industry to achieve:

• Ultrapure water meeting international standards

• Maximum electrolysis efficiency

• Lower operational costs

• Longer electrolyzer lifespan

Quantitative Factors to Consider

Ultrapure Water Quality

• Requirement: > 18 MΩ-cm (≤ 0.056 µS/cm), TOC < 1 ppb.

• Impact:

  • Reduces water conductivity → boosts electrolysis efficiency by ~2–5%.

  • Prevents PEM membrane corrosion → extends electrolyzer life from 5–7 years to 7–10 years (estimated by OEMs like Nel, Plug Power).

Ionic Impurity Removal

• Target Levels: Ca²⁺, Mg²⁺, Na⁺, Cl⁻, SO₄²⁻, SiO₂ at < 1–5 ppb each.

• If untreated:

  • Increased electrical resistance → efficiency drops 3–10%.

  • Electrode fouling and corrosion → maintenance costs rise 20–30%.

Reduced Wastewater and Rinse-In Time

• UltraClean™ resins reduce initial rinse time from 20–24 hours to 6–8 hours, saving:

  • Water: 30–50% (tens of m³ per startup).

  • Downtime: 1–2 fewer days → 5–10% OPEX savings.

Hydrogen Production Efficiency

• With UPW, electrolysis achieves ~70–80% HHV efficiency versus 60–70% with lower water quality.

• Yield increase: 5–8% more hydrogen at the same energy input.

• Example: For 1,000 kg H₂/day → 50–80 kg additional hydrogen/day (~1.8–3 tons/year).

Maintenance and Replacement Costs

• Reduced contaminants and corrosion extend membrane/electrode lifespan by 30–50%, lowering replacement costs (up to $0.5–1 million for MW-scale systems).

• Annual maintenance downtime decreases from 10 days to 5–6 days → ~$100,000–200,000/year in economic benefit.

Conclusion

• Key quantitative benchmarks:

  • Water quality > 18 MΩ-cm, TOC < 1 ppb

  • 30–50% downtime reduction

  • 30–50% wastewater reduction

  • 5–8% hydrogen efficiency increase

  • 30–50% longer electrolyzer lifespan

• These figures are not explicitly stated in the brochure but can be sourced from:

  • Ecolab’s UltraClean™ datasheets

  • OEM electrolyzer specifications (Nel, Plug Power, ITM)

  • White papers on water quality impacts in PEM/AEM/AEL electrolysis systems.