Pressuriz3D · 3D printing fabrication of tailored interfaces for pressurized Protonic Ceramic Electrolysis Cells

3D printing fabrication of tailored interfaces for pressurized Protonic Ceramic Electrolysis Cells

The MSCA fellowship project Pressuriz3D, launched on 1 July 2023, addresses a critical challenge in the deployment of protonic ceramic electrochemical cells (PCECs)—enabling high-efficiency, pressurised operation without the need for large and costly external containment vessels. PCECs have the potential to produce clean, dry, and compressed hydrogen directly from renewable sources at a lower temperature (300-650 °C) and with high efficiency (conversion rates of ≈80 %) compared to conventional solid oxide electrolysers. However, their industrial uptake has been limited by the difficulty of ensuring long-term material stability, reliable sealing, and cost-effective manufacturing for pressurised systems. In particular sealing for normal or pressurized operation is a critical issue due to chemical expansion in during hydration of the cells. Pressuriz3D combines advanced materials science with additive manufacturing to deliver a new generation of PCEC designs tailored for robust pressurised operation. The project aligns with EU strategic priorities in the European Green Deal, the EU Hydrogen Strategy, and REPowerEU, contributing to the scale-up of clean hydrogen production technologies essential for decarbonisation and energy resilience. In line with the Grant Agreement, the research is structured around three core objectives: 1. RO1 – Compatibility study Identify and validate ceramic electrolyte and electrode materials for PCEC construction, focusing on their chemical and mechanical compatibility with advanced glass-based sealants under high-temperature, humidified, and pressurised conditions. 2. RO2 – 3D printing of PCEC components Develop and optimise high-resolution additive manufacturing routes, including digital light process (DLP) and robocasting, to fabricate dense electrolytes, porous electrodes, and integrated glass-ceramic seals in complex geometries. 3. RO3 – Pressurised single repeating unit (SRU) demonstration Integrate the developed components into a PCEC SRU and evaluate electrochemical performance under pressurised gas conditions, including microstructural and durability analysis, to validate suitability for high-efficiency hydrogen production. By delivering novel sealing solutions and cost-efficient 3D printing methods for high-performance, pressurised PCECs, Pressuriz3D is expected to remove critical technological barriers, reduce system cost, and accelerate market readiness. The expected impact extends beyond the hydrogen sector, with potential application in fuel cells, solid-state reactors, and high-temperature gas separation technologies, thereby strengthening Europe’s position in clean energy innovation and advanced manufacturing.

Текст от CORDIS, на английски · Данни: CORDIS, © Европейски съюз