High-efficiency 1 MW Dynamic Electrolyser Unit for cost-efficient production of PtX-based green methanol

Project Information

HiFiMet

Grant agreement ID: 101145278

DOI

10.3030/101145278

EC signature date 9 February 2024

Start date 1 March 2024

End date 31 August 2026

Funded under

• The European Innovation Council (EIC)

Total cost

€ 11 522 500,00

EU contribution

€ 2 499 999,00

Coordinated by

DYNELECTRO APS
Denmark

Periodic Reporting for period 1 - HiFiMet (High-efficiency 1 MW Dynamic Electrolyser Unit for cost-efficient production of PtX-based green methanol)

Reporting period: 2024-03-01 to 2025-05-31

Summary of the context and overall objectives of the project

Europe’s transition to climate neutrality depends on scalable, efficient solutions for producing clean fuels. Hydrogen produced via electrolysis plays a central role in decarbonising hard-to-abate sectors such as industry, transport and power. Solid Oxide Electrolysis (SOE) is widely recognised as the most energy-efficient electrolysis technologies, yet it faces hurdles in durability, responsiveness and industrial integration.

This project addresses these challenges by developing and validating a 1 MW industrial-scale high-temperature electrolysis system using solid-oxide electrolysis (SOE) that operates under real-world, variable conditions. The overall objective is to demonstrate Dynelectro’s innovative “Dynamic Electrolyser Unit” (DEU) technology at megawatt scale. The DEU uses proprietary power electronics (which we call "AC:DC") and thermal integration to enable rapid load changes and ultra-low degradation. This unlocks compatibility with renewable energy fluctuations and industrial operations.

The project aims to set a new benchmark for high-efficiency hydrogen production with reduced lifecycle costs and enhanced operational flexibility. Dynelectro's technology can lower OPEX (excl. electricity) by 40% compared to standard SOE systems. Furthermore, SOE is known to be up to 90% efficient compared to AE/PEM which is approximately 60% efficient.

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 progressed through design, procurement and assembly of the 1 MW electrolyser unit using solid oxide cell (SOC) technology. Our key supply chain partner is SolydEra who have engineered one the more robust stack technologies.

DEVELOPMENT ACTIVITIES
======================
Key engineering milestones included the development of:
(i) a modular electrolysis stack architecture optimised for scale, based on proprietary long-lifetime solid oxide cells;
(ii) a custom thermal management system to stabilise high-temperature operation while enabling dynamic cycling;
(iii) and dynamic operation platform (called "AC:DC"), which allows rapid power ramping, enabling the unit to operate effectively under intermittent renewable input.

VALIDATION ACTIVITIES
====================
The electrolyser system underwent extensive pre-validation testing at Dynelectro’s facility to confirm stack durability and system efficiency. Testing showed stack degradation rates of less than 0.1% per 1,000 hours – among the lowest reported for SOE systems – while maintaining electrical efficiency above 85% at full load.

To support industrial integration, the unit was designed for pressurised steam input and is investigating interfaces for coupling with biogas upgrading systems. This lays the groundwork for producing renewable methane by combining hydrogen from SOE with CO2 from biogas.

As part of the project’s exploitation strategy, Dynelectro is developing a techno-commercial model in collaboration with leading industry stakeholders, including Yara and Fremsyn. This model demonstrates how high-efficiency solid oxide electrolysis can unlock new value chains by coupling low-cost renewable electricity with biogenic CO2 to produce renewable methane. By integrating Dynelectro’s dynamic electrolyser with Fremsyn’s biogas upgrading operations and leveraging Yara’s expertise in large-scale ammonia and hydrogen markets, the model showcases a scalable, sector-coupled solution that supports grid flexibility, enhances renewable gas yields, and accelerates decarbonisation across agriculture, energy and chemical sectors.

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)

The project is advancing high-temperature electrolysis through the development and ongoing assembly of a 1 MW solid oxide system designed for dynamic operation, high electrical efficiency and industrial integration. This represents a step change from conventional electrolysis technologies such as alkaline and PEM, which typically offer lower efficiency and limited thermal integration potential.

Dynelectro’s system incorporates several key innovations:
(i) solid oxide stacks with proven ultra-low degradation rates (less than 0.1% per 1,000 hours) based on over 23,000 hours of extended stack performance testing;
(ii) proprietary AC:DC power electronics platform that enables rapid power ramping while maintaining stable operation;
(iii) and a system architecture engineered for integration with CO2-rich gas streams, supporting the production of renewable methane and other e-fuels.

Once completed, the 1 MW system will push the performance frontier of solid oxide electrolysis and demonstrate its potential within Europe’s emerging hydrogen economy - particularly within industrial hubs, synthetic fuel production and sector-coupled fully integrated energy systems.

To enable full commercial deployment, several key enablers must be addressed. Large-scale demonstrations will be necessary to validate the technology’s economics, thermal integration and grid responsiveness at industrial scale. Strong partnerships with offtakers and system integrators, such as Yara and Fremsyn, will be critical for deploying the technology in operational environments. Access to green finance and the development of robust power-to-gas business models are also essential to support widespread adoption.

Further success will rely on a supportive regulatory framework, particularly in the areas of renewable gas certification, hydrogen blending and CO2 accounting. Continued progress on standardisation for system safety, integrated operations and performance certification will help streamline scale-up efforts.

Robust intellectual property protection will also be key to securing the competitiveness of European innovation in global markets. The progress made so far in this project highlights the potential of solid oxide electrolysis to support decarbonisation efforts and strengthen Europe’s energy independence.

Submodule (250-kW) which is the core part of the system

Head of Engineering in the early prototype

Side view of the submodule

Ultra-low degradation from the 23,000 hour stack performance testing