SustainaBlE SoluTions FOR recycling of end of life Hydrogen technologies

Project Information

BEST4Hy

Grant agreement ID: 101007216

DOI

10.3030/101007216

Project closed

EC signature date 4 December 2020

Start date 1 January 2021

End date 31 December 2023

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 1 586 015,00

EU contribution

€ 1 586 015,00

Coordinated by

PARCO SCIENTIFICO TECNOLOGICO PER LAMBIENTE ENVIRONMENT PARK TORINO SPA
Italy

Periodic Reporting for period 2 - BEST4Hy (SustainaBlE SoluTions FOR recycling of end of life Hydrogen technologies)

Reporting period: 2022-07-01 to 2023-12-31

Summary of the context and overall objectives of the project

BEST4Hy – "SustainaBlE SoluTions FOR recycling of End of Life Hydrogen Technologies" had the overall objective of identifying and developing viable recycling strategies, supported by innovative technologies, that will provide the best solution for recovering precious and critical materials from hydrogen technologies. More specifically, the project adapted existing recycling technologies and developed new ones up to TRL5 focusing on the treatment of EoL PEMFC and SOFC. The target materials recovered for recycling are platinum group materials, rare earth elements, cobalt and nickel, but also recoverable /recyclable components are considered such as ionomer and polymeric membrane. The processes managed to recover the membrane, 80% of the ionomer, to 95% of Pt from PEM and 80% of YSZ, Ni, La and Co from SOFC. Novel technologies were trialed for the treatment of PEM from water electrolysers. Three patents were filed.
The recycling technologies are evaluated for cost efficiency and environmental impact to ensure the materials recovered bring value to the European economy without harmful emissions or high energy costs. The recycling technologies maximise opportunities for both closed-loop and open-loop recycling. More specifically, for closed-loop recycling, Pt and membrane materials are delivered back for manufacturing membrane electrode assemblies (MEAs) and tested in single cells and full stacks, while both anode and cathode materials from EoL SOFCs are treated for direct recycling into cells. Re-manufacturing of new cells/stacks has included catalyst manufactured with 100% of recycled Pt in the manufacturing of PEMs stacks and 30% of recycled critical raw materials (Ni, YSZ and LSC) in SOFC cells manufacturing.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project validated the technologies developed at TRL5.
Recycling of PEMFCs: the project explored first different mechanical disassembly processes for PEMFC, to identify the more efficient method for obtaining a catalyst-coated membrane (CCM) free of contaminants, a prerequisite for maximising the recovery of platinum with the following processes. Hydrometallurgical treatment of CCM upscaled at TRL5 confirmed the very and consistent high yields (95%) of the process in the recovery of platinum as salt, a precursor for the synthesis of the catalyst used on PEM. A novel dismantling process was applied for the successful separation of the MEA and the CCM, obtaining 100% recovery of the membrane. Furthermore, a new process of simultaneous electroleaching of Pt from CCM and electrodeposition of Pt was successfully demonstrated and reached 95% recovery of metallic Pt. An alcohol dissolution process, applicable to both PEMFC and PEMWE, enabled the recovery of 80% ionomer and of a PGM rich solution, to be further processed through HMT. Three patent applications were filed around these novel technologies. MEAs were manufactured with catalyst synthetised with Pt salt issued from HMT processing of EoL PEMFC. Testing at different scales of single cells allowed to identify the best ink composition and evaluate opportunities for maximising use of recovered materials. CCMs to industrial scale were manufactured containing 100% recycled catalyst; they were tested in a short stack at industrial scale showing good performance when compared to commercial cells.
Recycling of SOFCs: an efficient procedure based on the adaptation and combination in a single step of hydrothermal and hydrometallurgical technologies was optimised in terms of yield and operating conditions to recover critical materials from EoL and scrap SOFCs. Up to 80% of materials were recovered. Other work concentrated on the recycling of LSC cathodes of EoL SOFC. The hydrometallurgical processes were optimized, to maximize the leaching efficiencies, the recovery yields and the purities of the recovered La and Co products. LSC was then synthetised from the recovered elements. Strict cooperation with the manufacturers of SOFC was key to ensuring the availability of EoL and/or scrap cells and to understanding specifications for recycled materials to be used in production of new cells/components. Up to 30% of the recovered materials were successfully incorporated into new cells.
Despite the low TRL of the BEST4Hy EoL technologies, a cradle-to-grave/ gate-to-gate LCA study of both PEMFC and SOFC was completed. A Overall, ten newly developed life cycle inventories (LCI) and LCA models for FCH technologies related to the recycling processes. In addition to the environmental LCA, the first innovative life cycle cost (LCC) model for the EoL technology within the FCH technologies was developed.
An update of the regulatory framework for the ecodesign and treatment of EoL FCH was performed, with a roadmap to standardisation traced. Training materials was developed showing the full processing of EoL fuel cells. Some 13 KERs were identified and their exploitation strategy traced.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Concerning the processing of EoL PEMFC, the project assessed the best disassembly method (hybrid manual/mechanic) and developed a new gaseous-phase dismantling process to maximise recovery of CCMs, hence supporting the achievement of high recovery percentages of interesting materials and components in the following phases. Two patent applications have been filed for the gaseous-phase dismantling process. Furthermore, BEST4Hy adapted a hydrometallurgical process and developed two novel processes (alcohol dissolution and electroleaching/electrodeposition) to recover Pt as salt precursors for the manufacture of catalyst for PEMFC, ionomer and metallic Pt. High yields were achieved: up to 95% recovery for Pt and 80% recovery for ionomer. One patent application was filed for the alcohol dissolution process, while the electroleaching/electrodeposition derive from a pre-existing patent. The recovered Pt salt was successfully synthetised into a “recycled catalyst” that was used to manufacture MEAS. Testing at different scales of single cells allowed to identify the best ink composition and evaluate opportunities for maximising use of recovered materials. CCMs to industrial scale were manufactured containing 100% recycled catalyst; they were tested at industrial scale showing good performance when compared to commercial cells.
Concerning EoL and scrap SOFC, a hydrothermal and a hydrometallurgical processes were successfully combined into a one-step process at a TRL5 scale to obtain YSZ and Ni from EoL/scrap SOFC. The target of 80% recovery of materials was attained. Furthermore, a novel process for the recovery of La and Co from the LSC cathode was developed at TRL3, issuing materials that could be synthetised into new LSC. Up to 30% of recovered YSZ, Ni and LSC were incorporated into new SOFCs.
All developed EoL processes with associated mass and energy balances (LCI) represent a significant advance for the LCA of SOFC manufacturing and EoL technologies, which were not previously available. Some ten newly developed life cycle inventories (LCI) and LCA models for FCH technologies related to the recycling processes were developed. In addition to the environmental LCA, the first innovative life cycle cost (LCC) model for the EoL technology within the FCH technologies was developed and the results based on Pt recycling via the HMT process from the PEMFC waste stack were presented as a case study.

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