Periodic Reporting for period 1 - Hy-SPIRE (Hydrogen production by innovative solid oxide cell for flexible operation at intermediate temperature)
Reporting period: 2024-02-01 to 2025-07-31
The Hy-SPIRE project aims at further boosting the potential of SOEL by lowering the operating temperature below 700°C, and increasing its flexibility in order to fit with RES generation profiles. Within the project, novel cells will be developed towards achieving strict KPIs such as low degradation equal to or lower than 0.75% per 1,000 h, operation at high current densities ca. 1.2 A/cm^2 and ability to operate dynamically and fast ramping. The goal will be reach by the means of developing and applying new materials, advanced manufacturing techniques and optimized cell and stack designs. The Hy-SPIRE project will aim at developing oxygen ion- and proton-conducting cells (O-SOE and P-SOE, respectively) on both, ceramic and metallic supports, therefore analysing broad range of technological possibilities. The new cells and stacks will go beyond the SoA technology in terms of designs, performance and operation. The consortium of the project brings together a recognized European stack manufacturer (SolydEra), top players in the development of materials for SOCs, expertise in fabrication as well as unique testing capacities and know-how in technology assessment. Techno-economic analysis, supported by the LCA will be used for the evaluation of project novelties and the market potential. The project will cover definition of barriers and research directions to achieve SRIA objectives such as reduction of hydrogen production cost to 3 €/kg by 2030, reduction of CAPEX 520 €/(kg/kW) and OPEX 45 €/(kg/kW). Moreover the technology of cells and stacks – the effects of Hy- SPIRE – will be designed for large-scale production, and tailored for coupling with RES and other industry sectors.
In the first 18 months the project has made substantial technical and scientific progress toward advancing solid oxide electrolysis cell, focusing on improving performance, durability, lowering operating temperature, and implementation of advanced deposition techniques.
A key achievement was the optimization of metal-supported cell architecture, where AISI 441 stainless steel was selected for its thermal and mechanical stability. Laser-drilled pores and tape-cast porous layers enabled efficient gas diffusion and strong adhesion of functional layers. Efforts to reduce degradation rates below 0.75%/1,000 hrs included the introduction of Ti-based mixed ionic-electronic perovskites on the fuel side, as well as on-going protective coatings development and optimization of microstructures of gas diffusion layers further contribute to durability.
The integration of selected Ln-doped ceria buffer layers via pulsed laser deposition significantly improved electrochemical performance, achieving 1.4 A/cm² at thermoneutral voltage without degradation. Electrode development focused on broadening the operating window and enabling high-current electrolysis. Moreover, PLD-fabricated LSCF/LSC oxygen electrodes demonstrated excellent performance. Interface engineering, particularly with PLD-deposited buffer layers, helped mitigate delamination and void formation.
To reduce the use of critical raw materials (CRM), thin electrolyte layers were developed using nanosuspension-based wet ceramic processing and advanced deposition techniques (PLD, PVD). These approaches enabled high performance with minimal material usage, supporting compact stack designs and improved thermal management. Ultra High-temperature Sintering (UHS) was successfully demonstrated, reducing sintering times from hours to minutes or even seconds.
The testing protocols for both oxygen-ion and proton-conducting cells were developed, incorporating EU harmonized standards as well as feedback from other EU on-going and finished projects. The base of the techno-economic model was developed and validated using literature and preliminary project data. Finally, a baseline Life Cycle Assessment (LCA) model was established, future iterations will assess the impact of alternative materials, fabrication techniques, and CRM reduction strategies on environmental performance.
A key achievement was the optimization of metal-supported cell architecture, where AISI 441 stainless steel was selected for its thermal and mechanical stability. Laser-drilled pores and tape-cast porous layers enabled efficient gas diffusion and strong adhesion of functional layers. Efforts to reduce degradation rates below 0.75%/1,000 hrs included the introduction of Ti-based mixed ionic-electronic perovskites on the fuel side, as well as on-going protective coatings development and optimization of microstructures of gas diffusion layers further contribute to durability.
The integration of selected Ln-doped ceria buffer layers via pulsed laser deposition significantly improved electrochemical performance, achieving 1.4 A/cm² at thermoneutral voltage without degradation. Electrode development focused on broadening the operating window and enabling high-current electrolysis. Moreover, PLD-fabricated LSCF/LSC oxygen electrodes demonstrated excellent performance. Interface engineering, particularly with PLD-deposited buffer layers, helped mitigate delamination and void formation.
To reduce the use of critical raw materials (CRM), thin electrolyte layers were developed using nanosuspension-based wet ceramic processing and advanced deposition techniques (PLD, PVD). These approaches enabled high performance with minimal material usage, supporting compact stack designs and improved thermal management. Ultra High-temperature Sintering (UHS) was successfully demonstrated, reducing sintering times from hours to minutes or even seconds.
The testing protocols for both oxygen-ion and proton-conducting cells were developed, incorporating EU harmonized standards as well as feedback from other EU on-going and finished projects. The base of the techno-economic model was developed and validated using literature and preliminary project data. Finally, a baseline Life Cycle Assessment (LCA) model was established, future iterations will assess the impact of alternative materials, fabrication techniques, and CRM reduction strategies on environmental performance.
The begging phase of the project has delivered several technical advancements that go beyond the current state of the art in solid oxide electrolysis cell technology. One of the most notable achievements is the development of metal-supported cells using AISI 441 stainless steel. The precise laser-drilling of pores and tailored microstructure of the gas diffusion layers represent a significant step forward in cell architecture, enabling more compact and thermally manageable stack designs. Another breakthrough is the implementation of Ln-doped ceria buffer layers deposited via PLD for O-SOE. This approach has demonstrated superior interface stability, reduced degradation, and improved electrochemical performance at high current densities. The PLD technique also enables precise control over layer thickness and composition, contributing to reduced use of critical raw materials and paving the way for scalable fabrication of high-performance cells. In parallel, the pathway to optimized parameters of UHS for proton-conducting SOECs (P-SOE) was established.
Upscaling, long-term testing, and further optimization are essential to validate performance under real-world conditions and to confirm their commercial viability.
To ensure successful uptake and exploitation of these innovations, several key needs must be addressed:
- Further research and demonstration at stack and system levels to validate durability, performance, and integration potential.
- Further IPR protection and technology transfer mechanisms (patent purity tests, know-how protection, analysis of whether a patent will be the best solution to protect the know-how).
- International collaboration to align with global standards and accelerate deployment.
Together, these results position the project at the forefront of SOE innovation, offering a pathway toward more efficient, scalable, and sustainable hydrogen production technologies.
Upscaling, long-term testing, and further optimization are essential to validate performance under real-world conditions and to confirm their commercial viability.
To ensure successful uptake and exploitation of these innovations, several key needs must be addressed:
- Further research and demonstration at stack and system levels to validate durability, performance, and integration potential.
- Further IPR protection and technology transfer mechanisms (patent purity tests, know-how protection, analysis of whether a patent will be the best solution to protect the know-how).
- International collaboration to align with global standards and accelerate deployment.
Together, these results position the project at the forefront of SOE innovation, offering a pathway toward more efficient, scalable, and sustainable hydrogen production technologies.