Innovative co-electrolysis systems and integration with downstream processes

Proposals should aim to accelerate the development of the co-electrolysis technology and its integration into real chemical synthesis process by proving the concept and the overall efficiency of the coupling between the co-electrolyser and the downstream process, mainly the catalytic reactor for the chemical synthesis. They should also contribute to resolving additional technological challenges on low-TRL level (cell/stack/stack module technology) to improve the stack operations for direct downstream process integration (downstream gas purity and composition, pressurised conditions) and the core technology impacting more drastically the lifetime (hence OPEX cost contribution) compared to steam electrolysis.

The project should cover the following elements:

• Adapt core technology and cell design to increase the robustness in the identified operating conditions and gas composition;
• Screening at cell or short-stack level different catalysts and operational parameters to achieve the required H2/CO ratio for further downstream processing including pressure, temperature, reactant purity. Investigation should encompass not only performances but also prevention of coke formation in the stack, stack module, system and afterwards;
• Assessing the optimal operating conditions of the co-electrolyser and of the downstream process at the scale of a short stack over durations above 3000h, with the aim of ensuring an optimised coupling of the two technologies, considering:
  • heat recovery from the fuel synthesis process in the co-electrolysis unit (steam generation, gas preheating, etc.);
  • the most effective strategy for cleaning up produced syngas, if necessary;
• Design integrated co-electrolyser and downstream reactor with ad hoc BoP to increase global efficiency and promote syngas production stability, supported by simulation tools and experimental validation. The study should analyse the effects of transient and off-design operation of the system, encompassing both startup and shutdown processes. Technological and economical impacts of recirculation of separated streams such as water (steam) and carbon dioxide have to be considered;
• Demonstrating the coupling at a relevant scale (size of the co-electrolyser >15 kW) between the co-electrolyser and the downstream reactor and evaluate its performance and durability over 2000 h minimum;
• Conducting a techno-economic and life cycle impacts analysis and a preliminary study of safety aspects of the integrated system.

Costs related to downstream process unit design and development will not be funded and the coupling should be performed in a location where such a reactor is available at the adequate size for a good matching with the co-electrolyser. An electrolyser manufacturer should be involved in the consortium for this topic. Participation of industrial partners in the integration downstream and valorisation of the co-electrolysis product is expected.

For activities developing test protocols and procedures for the performance and durability assessment of electrolysers and fuel cell components proposals should foresee a collaboration mechanism with JRC[[https://www.clean-hydrogen.europa.eu/knowledge-management/collaboration-jrc-0_en]] (see section 2.2.4.3 "Collaboration with JRC"), in order to support EU-wide harmonisation. Test activities should adopt the already published EU harmonised testing protocols[[https://www.clean-hydrogen.europa.eu/knowledge-management/collaboration-jrc-0/clean-hydrogen-ju-jrc-deliverables_en]] to benchmark performance and quantify progress at programme level.

For additional elements applicable to all topics please refer to section 2.2.3.2