Billionaire Forrest’s Fortescue officially opens new 2GW PEM hydrogen electrolyser factory in Australia

Electrolysers were designed in-house after initial deal with Plug Power fell through

An aerial photo of the new 2GW electrolyser factory in Gladstone, Queensland.
An aerial photo of the new 2GW electrolyser factory in Gladstone, Queensland.Photo: Fortescue

Green hydrogen developer Fortescue — led by billionaire Andrew Forrest — has officially opened its “world-leading” 2GW electrolyser factory in Queensland, Australia, which will produce proton-exchange membrane machines designed in-house.

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The Australian company — whose primary business is iron-ore mining — had originally set up a 50-50 joint venture with electrolyser maker Plug Power to build the factory, using Plug’s technology. But when the US manufacturer pulled out of the deal in January 2023 — 11 months after construction had begun, Fortescue decided to push on using technology designed by its own engineers.

Fortescue is yet to reveal any details about its machines, such as efficiency or cost, and the developer — which has yet to produce any green hydrogen — but says its new plant “will underpin our green hydrogen projects and that of others”.

The 15,000-square-metre facility, which Fortescue says is one of the first globally to house an automated assembly line, will be able to produce more than 2GW of PEM electrolyser stacks annually.

“We know that technology in this space moves very quickly so as well as producing electrolysers today, this facility also provides an amazing environment for our team to learn and then leverage that experience to drive innovation and develop the solutions of tomorrow,” said Fortescue Energy CEO Mark Hutchison.

“We will continue to research, manufacture, source and invest in new electrolyser technologies across the world to give us the best possible competitive position.”

The construction of the plant was “enabled” by support from the Queensland government — which provided an electrical substation, road network, communications and local water connection — and a A$44m (US$29m) grant from the Australian government.

“We are grateful for the Queensland and Federal Government’s vision and early support to help get us started,” said Forrest, who is Australia’s richest man. “Together we have laid the cornerstone for what will be a massive new manufacturing industry in Australia creating the potential for thousands of new green energy jobs.”

Hutchison added: “This facility positions Fortescue and Gladstone as a large-scale producer of what will be an increasingly sought-after commodity in the global shift to green energy.”

Fortescue is yet to say where its electrolysers will be utilised first, but they are not due to be used at the company’s planned 550MW Gibson Island project in Brisbane, Queensland, despite the new factory being a little over 500km away.

The preferred electrolyser supplier for Gibson Island is Plug Power, which would supply its machines from New York state, about 18,500km away.

In October 2023, when Fortescue announced Plug as the preferred supplier, a company spokesperson told Hydrogen Insight that the move was a reflection of an impending supply squeeze on electrolysers.

“Right now, there are not enough electrolysers in the world to support the amount of green hydrogen we are set to produce,” the spokesperson said at the time.

“That is why we are partnering with other world leaders in this space to secure our green energy supply chain, and we’re excited to secure capacity with Plug to help us achieve our goals.

“Fortescue has always said we are technologically agnostic and will always use the best solutions at the best price for shareholders for each of our projects.”

Also in October 2023, Fortescue signed a framework procurement agreement to buy 1GW of electrolysers from US start-up Electric Hydrogen, which is building massive 100MW electrolyser stacks.

The new Gladstone factory is part of a wider “Green Energy Manufacturing Centre” being developed at the 100-hectare site, which also includes a 50MW green hydrogen project and a hydrogen system testing facility.

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Published 8 April 2024, 09:01Updated 8 April 2024, 09:01