First Time Right
Electrolyzer development does not allow for endless prototype loops. Early
application of multiphysics modeling and simulation at the system level
is becoming increasingly important. With its advanced solutions, AVL not
only speeds up development and saves costs – it also unlocks the potential
to design better, more robust electrolyzers from day one.
interactions between stack, balance of plant (BoP) compo-
nents, control strategies, and dynamic load conditions – espe-
cially in combination with renewable energy sources.
AVL’s scalable simulation approach allows engineers to test
different materials, geometries, and operating scenarios
virtually – not only to boost efficiency, but to identify potential
failure modes early on. With growing emphasis on total cost
of ownership and uptime, the ability to simulate and optimize
lifetime has become a decisive differentiator.
Digital Twins for Durability
The long-term goal is a real-time Digital Twin of the electro-
lyzer system that monitors operating conditions continuously
and predicts degradation in response to fluctuating loads and
ambient influences. This would allow predictive maintenance
and adaptive control strategies that extend stack lifetime and
lower the levelized cost of hydrogen.
AVL is already laying the foundation for this vision. By com-
bining data-driven models with physics-based simulation, and
calibrating these models against experimental results, highly
accurate lifetime prediction is now within reach. For a tech-
nology sector defined by long investment cycles and steep
learning curves, this is a game changer.
Unlocking Lifetime Potential Through Simulation
As global momentum around green hydrogen continues to
increase, electrolyzer technology is stepping into the spot-
light. Whether based on proton exchange membrane (PEM),
anion exchange membrane (AEM), alkaline, or solid oxide (SO)
technology, all electrolyzer systems face similar development
challenges: efficiency, cost, scalability, and – most critically –
lifetime.
Traditional hardware-based validation methods reach their
limits when systems must meet lifetime requirements of up to
100,000 operating hours. This is why simulation is no longer
a supporting tool – it is a strategic enabler. AVL’s simulation
platforms AVL FIRE™ M and AVL CRUISE™ M provide detailed
insights into flow dynamics, thermal effects, and electrochem-
ical processes. These insights form the basis for understand-
ing degradation mechanisms and simulating component
longevity – long before a physical prototype is built.
From Stack to System – and Back Again
Stack performance alone does not determine overall efficiency
or durability. Design choices such as membrane thickness or
system pressure may appear beneficial at cell level but might
compromise overall system performance. Simulation enables
developers to evaluate the entire system, accounting for the
How Simulation Drives
Electrolyzer Efficiency and
Lifetime from Day One
2025