Periodic Reporting for period 1 - HERAQCLES (New manufacturing approaches for Hydrogen Electrolysers to provide Reliable AEM technology based solutions while achieving Quality, Circularity, Low LCOH, high Efficiency and Scalability)
Berichtszeitraum: 2023-06-01 bis 2024-11-30
HERAQCLES stands for New Manufacturing Approaches for Hydrogen Electrolysers To Provide Reliable AEM Technology Based Solutions While Achieving Quality, Circularity, Low LCOH, High Efficiency And Scalability.
Project HERAQCLES delivers an operational 25kW electrolyser stack including balance-of-plant based on AEM technology to validate both our novel design-for-manufacturing architecture and innovative components developed for automated production processes.
AEM electrolysis offers a more attractive cost/performance ratio compared to state-of-art PEM electrolysis because these is no need to utilise precious group metals in stack components like catalysts, porous transport layers and bipolar plates for generating hydrogen at reasonably high current density.
Current stack manufacturing processes face bottlenecks limited by many separate components, manual assembly and lack of tooling due to low production numbers.
The project focusses on increasing Manufacturing Readiness Level from 4 to 5 by collectively advancing all components to comply with automated manufacturing processes at industrial scale: forming of metal plates, 3D-screen printing porous layers, pilot-scale synthesis of membrane polymers and catalyst. Validation occurs in three yearly loops using single cell, short stack and full 25kW stack configurations, where test results are benchmarked against commercially available options to highlight critical improvements of composition, functionality and recyclability.
The experienced consortium brings together a unique combination of know-hows acquired in previous projects (e.g. Anione) and manufacturing capabilities provided by strong representation from industrial partners (6 out of 8). If successful, the final qualified stack prototype can be scaled-up quickly.
Finally, a business plan is established comprising of a technology roadmap, an analysis of premium applications, an overview of product-market combinations and feasible market development plans.
Project HERAQCLES delivers an operational 25kW electrolyser stack including balance-of-plant based on AEM technology to validate both our novel design-for-manufacturing architecture and innovative components developed for automated production processes.
AEM electrolysis offers a more attractive cost/performance ratio compared to state-of-art PEM electrolysis because these is no need to utilise precious group metals in stack components like catalysts, porous transport layers and bipolar plates for generating hydrogen at reasonably high current density.
Current stack manufacturing processes face bottlenecks limited by many separate components, manual assembly and lack of tooling due to low production numbers.
The project focusses on increasing Manufacturing Readiness Level from 4 to 5 by collectively advancing all components to comply with automated manufacturing processes at industrial scale: forming of metal plates, 3D-screen printing porous layers, pilot-scale synthesis of membrane polymers and catalyst. Validation occurs in three yearly loops using single cell, short stack and full 25kW stack configurations, where test results are benchmarked against commercially available options to highlight critical improvements of composition, functionality and recyclability.
The experienced consortium brings together a unique combination of know-hows acquired in previous projects (e.g. Anione) and manufacturing capabilities provided by strong representation from industrial partners (6 out of 8). If successful, the final qualified stack prototype can be scaled-up quickly.
Finally, a business plan is established comprising of a technology roadmap, an analysis of premium applications, an overview of product-market combinations and feasible market development plans.
WP1: In the first months, project management procedures have been installed, such as an administrative toolset, a data management plan and a detailed risk management plan.
WP2: Monolithos has received from Schaeffler and CNR, spent anion and proton exchange membrane water electrolyzer MEAs, with CRM (Pt and Ir) and non-CRM (Ni, Fe , Mo) electrodes. The electrodes have been subjected to delamination and electrocatalyst qualitative and quantitative analysis, in order to apply hydrometallurgical MONOLITHOS method to recovery CRM and non-CRM materials. Additionally, perform Life Cycle Analysis studies to evaluate the environmental impact of the process, identify areas of high environmental impact and explore alternative options for reducing energy consumption, CO2 emissions, and waste generation.
WP3: Deep state-of-the art from scientific and technical sources allows to select the best protocols for AEM materials and membrane testing. Bibliographical review based on membrane performance show that Sustainion 37-50 Grade T from Dioxide Materials or Aemion from Ionomer Innovations would be good reference for Loop 1. Experimental work : equipment tools build-up is in progress. AEM Material : formulations, using experimental design approach, are selected and preliminary casting test casting of liquid formulations have started.
WP4: NiFe layered double-hydroxides (LDH) anode electro-catalysts developed (BET 116 m2/g; XRF: 85:15 at. %; XRD: PS=5nm); 40 % Ni0.8Mo0.2/C cathode electro-catalysts developed (XRF: 80:20 at. %; XRD: PS= 10 nm); Development of printing pastes (316L) with pore forming agents; Designing of printing screens according to a together with Schaeffler defined geometry and printing of first samples (316L); Testing of debinding of the developed pastes and first sintering trial. Samples are now being studied for achieved material properties such as porosity and successful debinding of all Carbon.
WP5: Design loops to adapt existing PEM platform to AEM technology. Align on components and test rig design according to our Stack specification.
WP 6: The development of a system for protype stack testing is in the beginning of engineering phase. Process flow diagram is created and a start is made on the mass and energy balance. Risk is that we are highly dependent on decisions that are still to be made in the stack design that could impact the design of the protype. Close collaboration with Scheaffler on this topic is needed (and organized already) to mitigate this risk.
WP 7: A project identity, a logo, flyer, website have been finished for communication activities. A communication, exploitation and dissemination plan has been made and uploaded.
WP2: Monolithos has received from Schaeffler and CNR, spent anion and proton exchange membrane water electrolyzer MEAs, with CRM (Pt and Ir) and non-CRM (Ni, Fe , Mo) electrodes. The electrodes have been subjected to delamination and electrocatalyst qualitative and quantitative analysis, in order to apply hydrometallurgical MONOLITHOS method to recovery CRM and non-CRM materials. Additionally, perform Life Cycle Analysis studies to evaluate the environmental impact of the process, identify areas of high environmental impact and explore alternative options for reducing energy consumption, CO2 emissions, and waste generation.
WP3: Deep state-of-the art from scientific and technical sources allows to select the best protocols for AEM materials and membrane testing. Bibliographical review based on membrane performance show that Sustainion 37-50 Grade T from Dioxide Materials or Aemion from Ionomer Innovations would be good reference for Loop 1. Experimental work : equipment tools build-up is in progress. AEM Material : formulations, using experimental design approach, are selected and preliminary casting test casting of liquid formulations have started.
WP4: NiFe layered double-hydroxides (LDH) anode electro-catalysts developed (BET 116 m2/g; XRF: 85:15 at. %; XRD: PS=5nm); 40 % Ni0.8Mo0.2/C cathode electro-catalysts developed (XRF: 80:20 at. %; XRD: PS= 10 nm); Development of printing pastes (316L) with pore forming agents; Designing of printing screens according to a together with Schaeffler defined geometry and printing of first samples (316L); Testing of debinding of the developed pastes and first sintering trial. Samples are now being studied for achieved material properties such as porosity and successful debinding of all Carbon.
WP5: Design loops to adapt existing PEM platform to AEM technology. Align on components and test rig design according to our Stack specification.
WP 6: The development of a system for protype stack testing is in the beginning of engineering phase. Process flow diagram is created and a start is made on the mass and energy balance. Risk is that we are highly dependent on decisions that are still to be made in the stack design that could impact the design of the protype. Close collaboration with Scheaffler on this topic is needed (and organized already) to mitigate this risk.
WP 7: A project identity, a logo, flyer, website have been finished for communication activities. A communication, exploitation and dissemination plan has been made and uploaded.
Too early to report project results.
The project aims to achieve the following objectives that clearly represent a significant progress beyond the state for the art:
Use of non-critical raw materials (Ni, Fe, Mo catalysts) at relatively low loadings 2-5 mg/cm2 and cheap hydrocarbon membranes (CRMs ~0.0 mg/W) combined to continuous manufacturing processes and fully functional automated electrolysis stack manufacturing.
The project aims to achieve the following objectives that clearly represent a significant progress beyond the state for the art:
Use of non-critical raw materials (Ni, Fe, Mo catalysts) at relatively low loadings 2-5 mg/cm2 and cheap hydrocarbon membranes (CRMs ~0.0 mg/W) combined to continuous manufacturing processes and fully functional automated electrolysis stack manufacturing.