Periodic Reporting for period 1 - PressHyous (PRESSurized HYdrogen prOdUced by high temperature Steam electrolysis)
Reporting period: 2023-09-01 to 2025-02-28
The EU Commission has identified the production and use of clean H2 has a key lever for the industry decarbonation, as fuel for transportation and storage vector for renewable electricity on a large scale. RePowerEU plan set out the target of doubling the EU renewable H2 in the coming years. To achieve this ambition, the EU needs to upscale significantly the domestic manufacturing capacities with innovative equipment.
Electrolysers appear as a competitive solution to reach the clean H2 production level set by the EU. However, the use of H2 requires various pressure levels depending on the chosen processes and applications, which systematically involves additional pressurisation steps, after the production, to allow storage, transportation or use.
The compression of H2 is very energy-intensive, especially for the first bars. Hence, producing pressurised H2 directly in the electrolyser can bring major relief on the compression costs, reduce the technological complexity and positively impact the global process efficiency and furthermore a potentially smaller footprint.
In this context, PressHyous, an EU R&D project funded by the Clean H2 partnership, aims to produce low-carbon pressurised H2 at reduced cost, around 3€/kg by 2030. It will prove the concept through the operation of a 20 kWe pressurised lab-scale device (eq. 13.5 kg H2/day). This lab-scale device will be composed of a Solid Oxide Electrolysis (SOEL) stack located in a pressurised vessel, and will be operated up to 30 bar at, at least, 1 A/cm², close to the thermoneutral voltage during 4000 hours. The project also aims to investigate an innovative stack concept, without pressure vessel, thus reducing the cost of Balance of Plant, by testing this solution up to 10 bar on a short stack scale, at similar current density to the stack operated in the pressurised vessel. To reach objectives, both stacks will integrate optimised components, notably electrochemical cells and sealings, improved for pressurised operating. To complement the practical testing of the PressHyous concepts, the project will deliver model-based insights for H2 production under pressure for up to 5 identified use cases, on expectable performances of both stack concepts (with or without pressurised vessel) towards large scale developments up to 100s MWe, coupled with techno-economic and life-cycle analysis.
Electrolysers appear as a competitive solution to reach the clean H2 production level set by the EU. However, the use of H2 requires various pressure levels depending on the chosen processes and applications, which systematically involves additional pressurisation steps, after the production, to allow storage, transportation or use.
The compression of H2 is very energy-intensive, especially for the first bars. Hence, producing pressurised H2 directly in the electrolyser can bring major relief on the compression costs, reduce the technological complexity and positively impact the global process efficiency and furthermore a potentially smaller footprint.
In this context, PressHyous, an EU R&D project funded by the Clean H2 partnership, aims to produce low-carbon pressurised H2 at reduced cost, around 3€/kg by 2030. It will prove the concept through the operation of a 20 kWe pressurised lab-scale device (eq. 13.5 kg H2/day). This lab-scale device will be composed of a Solid Oxide Electrolysis (SOEL) stack located in a pressurised vessel, and will be operated up to 30 bar at, at least, 1 A/cm², close to the thermoneutral voltage during 4000 hours. The project also aims to investigate an innovative stack concept, without pressure vessel, thus reducing the cost of Balance of Plant, by testing this solution up to 10 bar on a short stack scale, at similar current density to the stack operated in the pressurised vessel. To reach objectives, both stacks will integrate optimised components, notably electrochemical cells and sealings, improved for pressurised operating. To complement the practical testing of the PressHyous concepts, the project will deliver model-based insights for H2 production under pressure for up to 5 identified use cases, on expectable performances of both stack concepts (with or without pressurised vessel) towards large scale developments up to 100s MWe, coupled with techno-economic and life-cycle analysis.
1. PressHyous will improve cell, stack (including interconnects, sealings, interconnect protective coatings, etc.) and BoP (e.g. vessels, heat exchangers, etc.) to be used in pressurised operation (up to 30 bar at a current density of at least 1 A/cm²).
At this stage of the project :
-A cell that has exceeded 1 A/cm² at thermoneutral voltage (TNV) under different conditions of pressure. Durability tests have been conducted at atmospheric pressure, showing very low degradation of the cell after a break-in period during which cells typically degrade more significantly. Durability studies under pressurised conditions still need to be carried out.
-New sealings have been qualified up to 20 bar,
-A BoP is partially defined.
2. PressHyous will design and validate the long-term operation of a lab-scale device comprising a SOEL stack and a pressure vessel (up to 30 bar) at the scale of 20 kWe (eq. 13.5 kg H2/d).
At this stage of the project, a prototype design which has progressed well (although a three-month delay has been announced).
3. PressHyous will investigate a promising Pressurised Stack concept without pressure vessel relieving the cost of BoP. This will be tested up to 10 bar at short stack scale, with a similar current density to the stack operated in a pressurised vessel.
At this stage of the project, a P-stack which has reached above 1 A/cm² at TNV and 7 bar, validating the PressHyous cell with a large active area.
4. PressHyous will deliver model-based insights for H2 production for up to 5 identified use cases, on expectable performances of both stack concepts towards large scale developments, in strong link with TEA and LCA.
At this stage of the project, 7 use cases have been defined in strong link with AB members. The concept designs for 2 use cases has been defined, followed by a preliminary safety analysis
5. PressHyous will perform a TEA and a LCA of up to 5 identified use cases showing the applicability and the benefits of the developed technologies and its 2 stack concepts versus AEL and PEMEL operating under pressure.
At this stage of the project, TEA and LCA methodologies are in place, and the first case studies are currently under analysis. An eco-design tool has been shared among the partners to support the implementation of this methodology within the project.
At this stage of the project :
-A cell that has exceeded 1 A/cm² at thermoneutral voltage (TNV) under different conditions of pressure. Durability tests have been conducted at atmospheric pressure, showing very low degradation of the cell after a break-in period during which cells typically degrade more significantly. Durability studies under pressurised conditions still need to be carried out.
-New sealings have been qualified up to 20 bar,
-A BoP is partially defined.
2. PressHyous will design and validate the long-term operation of a lab-scale device comprising a SOEL stack and a pressure vessel (up to 30 bar) at the scale of 20 kWe (eq. 13.5 kg H2/d).
At this stage of the project, a prototype design which has progressed well (although a three-month delay has been announced).
3. PressHyous will investigate a promising Pressurised Stack concept without pressure vessel relieving the cost of BoP. This will be tested up to 10 bar at short stack scale, with a similar current density to the stack operated in a pressurised vessel.
At this stage of the project, a P-stack which has reached above 1 A/cm² at TNV and 7 bar, validating the PressHyous cell with a large active area.
4. PressHyous will deliver model-based insights for H2 production for up to 5 identified use cases, on expectable performances of both stack concepts towards large scale developments, in strong link with TEA and LCA.
At this stage of the project, 7 use cases have been defined in strong link with AB members. The concept designs for 2 use cases has been defined, followed by a preliminary safety analysis
5. PressHyous will perform a TEA and a LCA of up to 5 identified use cases showing the applicability and the benefits of the developed technologies and its 2 stack concepts versus AEL and PEMEL operating under pressure.
At this stage of the project, TEA and LCA methodologies are in place, and the first case studies are currently under analysis. An eco-design tool has been shared among the partners to support the implementation of this methodology within the project.
PressHyous is expected to contribute significantly to shaping the overall perception of SOEL for H2 production under pressure. It aims to drive technological progress for SOEL, assess the economic implications of its implementation for involved partners and, more generally, for the H2 sector. The project focuses particularly in evaluating the effect of pressure on the LCOH for SOEL technology, comparing it with other electrolysis technologies already operating under pressure, and generating positive impacts on both society and the environment.
An assessment of the impacts achieved by M18 is presented in D1.6 in terms of knowledge and IPR, public interest and dissemination, technological, socio-economical and environmental impacts. The most significant technological ones are summarized below:
Achieved M1-M6:
- Developed characterization protocols for SOEL cells under pressurized conditions,
- Defined use cases with the AB,
- Implemented TEA and LCA methodologies,
- Identified the prototype installation site.
Achieved M6-M18:
- Designed and manufactured three generations of SOEL cells, with testing up to 10 bar pressure. Performance targets were met or exceeded for current density and steam conversion,
- Continuous improvements on the P-stack concept, achieving key performance indicators at 7 bar and 750°C,
- Identified and studied components for a 20 kWe lab-scale device, considering installation constraints,
- Selected 3 relevant use cases for system design and modelling, supporting TEA and feedback for development,
- Completed initial LCA and TEA reports and conducted an LCA workshop to deepen partner expertise.
The majority of the actual impact will occur once both stack concepts are fully designed and operational. This will help demonstrate the viability of HP SOEL technology for industrial use, and increase the confidence in SOEL as a technology capable of decarbonising hard-to-abate industries.
An assessment of the impacts achieved by M18 is presented in D1.6 in terms of knowledge and IPR, public interest and dissemination, technological, socio-economical and environmental impacts. The most significant technological ones are summarized below:
Achieved M1-M6:
- Developed characterization protocols for SOEL cells under pressurized conditions,
- Defined use cases with the AB,
- Implemented TEA and LCA methodologies,
- Identified the prototype installation site.
Achieved M6-M18:
- Designed and manufactured three generations of SOEL cells, with testing up to 10 bar pressure. Performance targets were met or exceeded for current density and steam conversion,
- Continuous improvements on the P-stack concept, achieving key performance indicators at 7 bar and 750°C,
- Identified and studied components for a 20 kWe lab-scale device, considering installation constraints,
- Selected 3 relevant use cases for system design and modelling, supporting TEA and feedback for development,
- Completed initial LCA and TEA reports and conducted an LCA workshop to deepen partner expertise.
The majority of the actual impact will occur once both stack concepts are fully designed and operational. This will help demonstrate the viability of HP SOEL technology for industrial use, and increase the confidence in SOEL as a technology capable of decarbonising hard-to-abate industries.