Solid Oxide Based Electrolysis and Stack Technology with Ultra-High Electrolysis Current Density (>3A/cm<sup>2</sup>) and Efficiency

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Abstract

Hydrogen, a valuable commodity gas, is increasingly recognized as an important fuel and energy storage pathway of the future. This project aims to develop an innovative solid oxide based electrolysis cell and stack technology with ultra-high steam electrolysis current (>3A/cm2) for potentially ultra-low-cost, highly efficient hydrogen production from diverse renewable sources. In this project, solid oxide based high power density cells (HiPoD cells) were developed. Those cells demonstrated capability of operating at ultra-high electrolysis current density of 6 A/cm2 at 1.67V. During a long term steady state electrolysis test, a HiPoD cell was operated for more than 1000 hours at 3 A/cm2 with a low degradation rate of 1.8% per 1000 hours. A 20-cell electrolysis stack was built using HiPoD cells and an ultra-compact, low-cost stack design platform. This stack was used to explore the boundaries of high current density electrolysis operation and achieved an incredible stack current density of 3 A/cm2 with an average cell voltage of only 1.493 V. The stack was further operated in steady-state electrolysis at 2 A/cm2 for more than 1000 hours with an overall degradation of 0.57% per 1000 hours. With an improved understanding of electrolysis operation at ultra-high current density, a new compact stack architecture (CSA) design with scalability up to 55 kW (or 38 kg H2 per day) was tested. A number of 45-cell CSA stack was built and demonstrated 10 kW and 245 g/hr hydrogen production at 1.8 A/cm2 electrolysis current density. In addition to cell and stack development, a preliminary system design was developed by integrating the inputs from electrochemistry, cell/stack performance data, and system level implications of configuration and operational parameters. A module design was created based on a circular array of six stacks surrounded in a cool pressure vessel. Further architectural and controls strategies such as stack power control and instrumentation were determined through the development of the module. A comprehensive techno-economic study of an ultra-high current density SOEC system integrated with renewable energy sources has been conducted. To determine the estimated cost of hydrogen for the system, the H2A Current Distributed Hydrogen Production Model version 3.101 was applied. Annual system production cases at both commercial and industrial electricity rates as per the H2A model was analyzed. The option of meeting DOE 2020 Advanced Electrolysis Technologies targets were discussed. Feedstock electricity represents the bulk of projected hydrogen cost with either electricity rate. At an annual production volume of 250 units, H2A hydrogen cost of $2.3/kg can be achieved at electricity cost around 3.5¢/kWh.

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