FEST realizes first 2.5 MW electrolyser for Bosch

Initial technological operation of the Hybrion stacks from Bosch in an industrial electrolysis system

The plant realized by FEST in Bamberg represents a technological milestone: For the first time in the world, Bosch Hybrion stacks are being operated in a complete electrolysis system and are actively producing hydrogen on an industrial scale. The commissioning serves Bosch as a reference point for evaluating stack performance under industrial load profiles, variable operating scenarios and complete system integration.

Project context and objectives

With the construction of its own electrolyzer at the Bamberg site, Bosch is expanding its development and test infrastructure for hydrogen technologies with a real system close to production. FEST was responsible for the complete system planning, container architecture, plant integration and commissioning of a 2.5 MW PEM electrolyzer, which is seamlessly integrated into the Bosch hydrogen landscape. The system is primarily used for the continuous supply of internal test benches and at the same time forms a modular building block for later industrial scaling up to the >50 MW range.

The PEM electrolysis system consists of two Hybrion stacks (1.25 MW each), manufactured at the Bosch plant in Bamberg. FEST integrated these stacks into a complete system consisting of water treatment, power electronics/rectifier for 2.5 MW DC supply, process and safety control, gas plant technology including gas treatment, drying and pressurization, operating and diagnostic software.

The stacks achieve an H₂ production rate of approx. 23 kg/h each. Under full load, this results in a total rate of >1,000 kg/day, which means that the system meets all the criteria for renewable hydrogen of EU-RED-II (proof of electricity, temporal correlation, proof of origin).

This high production rate is crucial for supplying the various consumers within the Bosch hydrogen landscape. This includes a test stand in which fuel cell drive systems (Fuel Cell Power Modules, FCPM) are operated under continuous load. The electrolyzer continuously feeds hydrogen into the so-called lifetime container via an internal pipeline network, in which the FCPM systems are tested for durability and performance stability.

The electrolyser is also integrated into an energy cycle: The electricity generated in the fuel cell systems is fed back into the overall system and contributes to supplying the electrolyser. This enables the simulation of realistic grid dynamics as well as changing load and partial load conditions.

The hydrogen produced on site can also be stored in a 21 m high pressure storage tank at up to 50 bar. This storage connection is used to cover peak loads, to decouple generation and consumption over time and for use in other test and analysis environments.

Summary

The integration of the electrolyser into this overall environment creates a scalable platform that Bosch uses for research, validation and the further development of future product generations in the areas of fuel cells and electrolysis. The combination of locally produced hydrogen, integrated storage and coupled test environments enables 24/7 continuous industrial operation that meets the requirements of near-series development processes.

Pictures: Bosch