RFPs: Innovative Co-Electrolysis Systems and Integration with Downstream Processes

Co-electrolysis technology has a relevant impact on hydrocarbon synthetic production processes (e.g. Fisher-Tropsch, ethylene and methanol routes), which is gaining continuous interest for the production of e-fuels (e.g. Sustainable Aviation Fuel (SAF), e-diesel, e-methane, etc) and other chemicals relevant for the chemical industry. With co-electrolysis carbon dioxide and steam are converted into syngas which is subsequently utilised in the downstream chemical processes to produce synthetic fuels or molecules of interest thereby enhancing overall energy efficiency. The primary benefit of the co-electrolysis lies in the ability to produce high-quality syngas in a single step, eliminating the need for extra H2/CO2 conversion processes.

Previous EU funded projects (Eco, HELMETH, SOPHIA, ELECTRA, SElySOs, eCOCO2, SUN2CHEM) have already assessed the feasibility of co-electrolysis and laid the groundwork for further improvements. However, heat integration between co-electrolysis systems and downstream processes can improve the overall efficiency of production with lower OPEX and flexible operation towards synthetic chemicals production, an aspect which has not been covered by those projects.

Scope

• Proposals should aim to accelerate the development of the co-electrolysis technology and its integration into real chemical synthesis process by proving the concept and the overall efficiency of the coupling between the co-electrolyser and the downstream process, mainly the catalytic reactor for the chemical synthesis. They should also contribute to resolving additional technological challenges on low-TRL level (cell/stack/stack module technology) to improve the stack operations for direct downstream process integration (downstream gas purity and composition, pressurised conditions) and the core technology impacting more drastically the lifetime (hence OPEX cost contribution) compared to steam electrolysis.
• The project should cover the following elements:
  • Adapt core technology and cell design to increase the robustness in the identified operating conditions and gas composition;
  • Screening at cell or short-stack level different catalysts and operational parameters to achieve the required H2/CO ratio for further downstream processing including pressure, temperature, reactant purity. Investigation should encompass not only performances but also prevention of coke formation in the stack, stack module, system and afterwards;
  • Assessing the optimal operating conditions of the co-electrolyser and of the downstream process at the scale of a short stack over durations above 3000h, with the aim of ensuring an optimised coupling of the two technologies, considering:
    • heat recovery from the fuel synthesis process in the co-electrolysis unit (steam generation, gas preheating, etc.);
    • the most effective strategy for cleaning up produced syngas, if necessary;
  • Design integrated co-electrolyser and downstream reactor with ad hoc BoP to increase global efficiency and promote syngas production stability, supported by simulation tools and experimental validation. The study should analyse the effects of transient and off-design operation of the system, encompassing both startup and shutdown processes. Technological and economical impacts of recirculation of separated streams such as water (steam) and carbon dioxide have to be considered;
  • Demonstrating the coupling at a relevant scale (size of the co-electrolyser >15 kW) between the co-electrolyser and the downstream reactor and evaluate its performance and durability over 2000 h minimum;
  • Conducting a techno-economic and life cycle impacts analysis and a preliminary study of safety aspects of the integrated system.

Objectives

• Project results are expected to contribute to the following objectives of the Clean Hydrogen JU SRIA:
  • Improve cell design/materials for an increased lifetime and high performance, and increase cell/stack robustness through improved thermal and process-flow management;
  • Develop new stack and balance of plant (BoP) designs;
  • Consider innovative system designs and improved balance of plant components to reduce cost.

Expected Outcomes

• Project results are expected to contribute to the following expected outcomes:
  • Efficiency improvement via an optimised system integrating co-electrolyser and downstream reactor, enhancing the efficiency of the power to final chemical process by reducing heat losses and recovering heat produced in the synthesis phase;
  • Optimised resource utilisation via integration with downstream processes, enabling the efficient utilisation of resources, such as waste heat or by-products, leading to overall process optimisation and reduced resource wastage;
  • Durability Improvement via an optimised operational strategy to prevent coke formation in the cells, stacks, stack modules and co-electrolyser system;
  • Cost reduction by optimising the production process and minimising energy consumption with integrated systems helping in reducing production and Total Cost of Ownership (TCO) costs, making the overall process more economically viable;
  • Environmental benefits via an integrated system contributing to reducing the environmental, economic and social impacts of synthetic chemical production, resulting in high reduction potential of greenhouse gas emissions, promoting circularity of materials and components, and, in general, improving the overall environmental impact of the process (in particular when associated with a reduction of the critical raw materials content);
  • Product diversification via integration with downstream processes, facilitating the production of a wider range of products and enabling diversification and opening up new market opportunities.
• Overall, the expected outcomes of integrating innovative co-electrolysis systems with downstream processes encompass improvements in efficiency, cost-effectiveness, environmental sustainability, technological advancement, and market competitiveness.

Eligibility Criteria

• Entities eligible to participate:
  • Any legal entity, regardless of its place of establishment, including legal entities from non associated third countries or international organisations (including international European research organisations) is eligible to participate (whether it is eligible for funding or not), provided that the conditions laid down in the Horizon Europe Regulation have been met, along with any other conditions laid down in the specific call/topic.
  • A ‘legal entity’ means any natural or legal person created and recognised as such under national law, EU law or international law, which has legal personality and which may, acting in its own name, exercise rights and be subject to obligations, or an entity without legal personality.
• To be eligible for funding, applicants must be established in one of the following countries:
  • the Member States of the European Union, including their outermost regions:
    • Austria, Belgium, Bulgaria, Croatia, Cyprus, Czechia, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden.

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