MaviS (Materials research and virtual sensor concepts as drivers of innovation for SOECs)
Synopsis
In the project "MaviS", Montanuniversität Leoben, AVL List GmbH, and Materials Center Leoben Forschung GmbH are collaborating on a new approach to improve the long-term stability of solid oxide electrolysis cells (SOECs), as well as to shorten development time and reduce development costs.
Duration: 01.06.2026 - 31.05.2029
Persons involved
Project leader: Edith Bucher
Project staff: Andreas Egger, Arijit Jana
Partner
- AVL List GmbH
- Materials Center Leoben Forschung GmbH
Abstract
Improving the long-term stability of solid oxide electrolysis cells (SOECs), combined with reducing development time and cost, is one of the most important and challenging requirements for the development of market-ready cells, stacks and systems. A particularly critical aging mechanism in SOECs is the change in the morphology of the cathode over time, especially the coarsening of the nickel phase, which reduces the electrochemically active area and increases the electrical resistance. This impairs performance and can lead to cell failure in the long term. To investigate these mechanisms, detailed in-situ insights into the ongoing changes in 3D morphology and their direct effects on electrochemical properties would be necessary. However, due to limited measurement capabilities and high costs, such analyses are difficult to perform. Electrochemical methods such as impedance spectroscopy (EIS) and current-density-voltage (i-V) curves can only monitor the cells to a limited extent, but do not provide in-situ insights into the exact degradation mechanisms. In the project, fuel electrodes with systematic variations are manufactured and applied to commercial half cells. Electrochemical tests using complementary methods such as EIS, i-V curves, Total Harmonic Distortion Analysis (THDA) and Intermodulation Distortion Analysis (IMA) determine characteristic signatures for specific damage mechanisms. Post-mortem analyses link these signatures to changes in morphology parameters. An AI-supported image characterization workflow enables the reduction of experimental effort and thus a more time- and cost-efficient post-mortem analysis. Virtual 3D reconstructions of morphology and data-driven modeling improve the understanding of degradation mechanisms. Generative AI is used to model the morphology changes. The coupling of data-driven and physical modeling provides a better understanding of cell degradation. Furthermore, this hybrid approach improves the significance of the influence of morphology changes on the lifespan of the cells. The methodology developed can be used in a future virtual sensor concept. This is to be understood as an online diagnostic tool developed beyond the project, which can draw conclusions about the type and stage of the degradation mechanisms by in-situ monitoring of various sensor signals of the cells, stacks or systems.
Financial support by the Klima- und Energiefonds within the call Energieforschung 2024 FTI -Fokusinitiativen is gratefully acknowledged.
AddEus (Additive manufacturing as a game changer for future-oriented electrochemical energy conversion and storage)
Synopsis
In the project "AddEus", the Chair of Physical Chemistry and the Chair of Structural and Functional Ceramics at Montanuniversitaet Leoben are working together with Lithoz GmbH on new methods for the production and characterization of solid oxide fuel cells and electrolysis cells. The focus of the project is on the development of innovative manufacturing methods and novel materials for a paradigm shift in cell design, which contribute to increasing power density, reliability and service life, reducing manufacturing costs and dependence from critical raw materials.
Duration: 01.01.2025 - 31.12.2027
Persons involved
Project leader: Edith Bucher
Project staff: Andreas Egger, Sayan Chattopadhyay
Partners
- Chair of Structural and Functional Ceramics, Montanuniversitaet Leoben
- Lithoz GmbH
Abstract
Solid oxide fuel cells and electrolysis cells are manufactured according to the state-of-the-art from two porous electrodes, a gas-tight electrolyte and a diffusion barrier. The state-of-the-art methods for manufacturing the layers (thicknesses in the 10-500 µm range) and the cells are screen printing, tape casting and conventional sintering. This conventional cell production currently results in a number of critical factors that limit the performance and long-term stability of the cells and thus prevent broad market introduction.
By researching new manufacturing technologies − such as tape casting of multi-materials, lithography-based 3D printing, new sintering technologies, and new electrode materials without critical raw materials − in the planned project, these critical factors can be eliminated. The aim is to implement a paradigm shift in cell design and cell production. This ambitious goal is addressed by the cooperation of the three project partners, who are proven experts with many years of experience in their respective project-relevant research fields.
The project contributes in particular to the tender priority 1 - Energy efficiency in energy conversion. As a result of the development of future-oriented energy technologies, a significant contribution will be made to environmental and climate protection and to the reduction of CO2 emissions. The competitiveness and competence leadership of all partners are clearly strengthened by these innovation-driven project goals. This has a positive impact on Austria as a business location and the achievement of climate neutrality in Austria by 2040 at the latest.
Financial support by the Klima- und Energiefonds within the Call "Energieforschung 2023" is gratefully acknowledged.
Design-SOEC (Knowledge-based design of solid oxide electrolysis cells for optimized hydrogen production)
Synopsis
In the project "Design-SOEC", Montanuniversitaet Leoben, Materials Center Leoben Forschung GmbH and AVL List GmbH are working on the development of a knowledge-based design approach for SOECs with optimized core components and improved reliability, energy efficiency and lifetime.
Duration: 01.04.2023 - 30.09.2026
Persons involved
Project leader: Edith Bucher
Project staff: Mehmet Aksoy, Andreas Egger, Sarah Eisbacher-Lubensky
Partner
- Materials Center Leoben Forschung GmbH
- AVL List GmbH
Abstract
The storage of large amounts of surplus energy is a key factor in the energy transition due to the increasing share of electricity from renewable, sometimes highly fluctuating energy sources. However, with the current state of the art energy systems, electrical energy can only be stored to a limited extent. Therefore, new innovative storage technologies, such as electrolysis and/or power-to-gas, are necessary. High-temperature electrolysis cells (SOECs) represent one of the most efficient and sustainable technologies for converting electrical energy into hydrogen or synthesis gas. However, unlike other electrolysis technologies such as alkaline electrolysis, SOEC systems have yet to be widely commercialized.
The design approach for state of the art SOEC cells is heavily based on experimental studies. The results are typically used as the basis for material and microstructure variations to incrementally improve the cells. Although work on microstructural characterization of the cells, as well as modeling/simulation, is performed in addition to electrochemical characterization, the respective results are often in an isolated context, so that new knowledge is generated - but not utilized.
The motivation for the project "Design-SOEC" is the need for a new development approach for SOECs, which combines competences in electrode/cell preparation and electrochemical characterization with detailed microstructural analyses and comprehensive simulations.
The overall goal of the project is to develop a knowledge-based design approach for SOECs with optimized core components and improved reliability, energy efficiency and lifetime. In particular, the design approach should also enable the scalability of the results from studies on button cells to cells on an industrially relevant scale.
Financial support by the Klima- und Energiefonds within the 8th Call "Energieforschung" is gratefully acknowledged.