Scalable metamaterial thermally sprayed catalyst coatings for nuclear reactor high temperature solid oxide steam electrolysis (METASIS)

Lead Research Organisation: Robert Gordon University
Department Name: School of Engineering

Abstract

The UK government has set an ambitious target of reaching net-Zero by 2050. Hydrogen has been considered to the energy vector to meet the target. However, a step change in technology is needed to produce enough green hydrogen to meet the target. One of the most promising new avenues for green hydrogen production is to combine the development of a highly active electrode layers for solid oxide steam electrolysis (SOSE) with the waste steam generated from nuclear power plant.

This project will develop an advance solution for zero emission hydrogen production by designing, fabricating, and testing thermally sprayed (air plasma spray) novel metasurface coatings of electrodes (tubular cell design) for solid oxide steam electrolysis (SOSE). While metasurface design for electrode is new, the tubular cell design has received increased attention in recent years, and among the different geometric design of electrode, the tubular design offers several advantages (e.g., alleviates issues associated with high temperature sealing as seals can be placed outside of high temperature zone, can have high active surface area, can be robust against thermal cycling, etc).

To achieve this, we need to benchmark the new design of electrolyser for high temperature (e.g., 700-900 C) steam deployment applications. The design will include structural (finite element analysis) and computational fluid dynamics analysis of the cell and develop understanding of its operational configurations with focus on structural and thermo-mechanical loads, incidental loads, and durability, including responses to the various loads (e.g., pressure fluctuations, temperature, and mechanical stresses). The material plays an important part in electrolysis, and therefore different electrode/electrolyte materials will be considered while manufacturing screen printing/spin coating method along with appropriate sintering processes. Following which, the cell (tubular samples as test coupon electrodes) will be fabricated using a combination of electrolyte. cathode, and anode from the materials list of choice using thermal spray (air plasma spray or APS) technique with cathode as metasurface at an industrial facility. We will then make solid oxide steam electrolyser prototype using the best design and materials choices. We will assess the overall viability of a modular design (a small container) with single tubular cell assembly. The single tubular assembly (or the electrolyser) will be tested at temperature as high as 900 C and will establish correlation between metasurface design and materials for optimum efficiency, including establishing mechanism of redox/transport processes and electro-chemical reactions. And finally, we will demonstrate the effect of materials, cell design and operational parameters on efficiency.

Developing electrolyser cells with enhanced hydrogen production and their scalable manufacturing can play an important role in enabling not only eco-friendly development but also cost-effective, reliable, and sustainable opportunities. This project has the potential to advance technology to produce green hydrogen and thus we will exploit the outcomes through a spin-out company or licensing to commercialise the product.
 
Description High temperature electrolyser design is not stable, not highly efficient, and not designed for high temperature steam produced, for example at nuclear reactors. Additionally, the challenge in the field of electrode manufacturing is their limited scalability (catalysts surface area). The innovation in the research included catalyst and cell design for efficient hydrogen production with stable structure for high temperature operation. Research objectives were achieved by designing, fabricating, and testing various test samples for solid oxide steam electrolysis (SOSE), for hydrogen production at 600-900 °C temperature range. Manufacturing of the cathode, electrolyte and anode layers were carried using a thermal spray and dip coating techniques, including metasurface manufacturing for enhanced reactive surface area.

In the current research, a tubular design was considered as it offers several advantages. The research task included: (a) benchmarking the tubular cell design for nuclear reactor heat transfer, (b) design optimisation using thermomechanical analysis, (c) material selection, manufacturing, and various analytical characterisation, and (d) cell testing at various temperature. Benchmarking goal was to identify the most efficient and effective design for transferring heat. Following which we carried selected range of design, simulations, manufacturing, and testing. For example, the results of thermomechanical analysis contributed to further improvements in the overall design of the tubular SOSE and foreseeing potential effects in the planned high temperature laboratory tests. The choice of materials and manufacturing and their arrangement played a crucial role in achieving desired properties and overall cell performance. Our experiments shows that the tubular electrolyser cell provides an improved performance, i.e., working at a higher current density for a given voltage, which means our design has higher hydrogen production rate, compared to the existing cells.
Exploitation Route Commercialisation of our tubular design with metasurface catalyst layer for enhanced reactive surface area will lead to lower levelized cost of production leading faster adoption of green hydrogen production technologies. Important to note that multi-material parts manufacturing in the current solid oxide steam electrolysis (SOSE) is not sufficient to meet future demand, so innovative and new manufacturing technologies are urgently required. Method through this research can be developed specifically to ramp up and support future growth and adapt to unexpected changes in the SOSE.

Cost is another factor that needs to be addressed to make hydrogen a viable energy source that provides an alternative to fossil fuels. Manufacturing modular SOSE, cost effective product designs and related techno-economic feasibility is a big challenge for such technology. Public acceptance, awareness, and long-term affordability are other issues that can impede the production of hydrogen through SOSE. This case study seeks to introduce economic benefit assessment for any future manufacturing needs.

Our research is still at the lab scale, we need to further upscale fabrication and optimise microstructures before it can be commercialised. However, our electrolyser has huge potential for accelerating green hydrogen economy providing cleaner environment for public.
Sectors Energy

Manufacturing

including Industrial Biotechology

URL https://www.rgu.ac.uk/news/news-2024/6855-rgu-researchers-make-steam-based-hydrogen-production-breakthrough
 
Description Public awareness and education: There are multiple gaps in the knowledge, and we are addressing those through future research and collaboration with stakeholders. We are communicating our research findings through various public dissemination routes (e.g., training through upskilling courses, talking to potential industrial collaborators where wastewater can be considered for electrolysis) and raising awareness using media (RGU Comms, social media) and fostering a more informed society.
First Year Of Impact 2023
Sector Agriculture, Food and Drink,Energy
 
Description Contributor to the workshop and report 'Materials for Nuclear Enabled Hydrogen'
Geographic Reach National 
Policy Influence Type Contribution to a national consultation/review
URL https://www.royce.ac.uk/news/new-royce-landscape-report-materials-for-nuclear-enabled-hydrogen/
 
Description Hydrogen Accelerator 2 (H2A) - Flexfunds research works funded by Department of Transport (Scotland) and managed by St Andrews University
Amount £14,950 (GBP)
Organisation University of St Andrews 
Sector Academic/University
Country United Kingdom
Start 02/2024 
End 03/2024
 
Description Materials Challenge Accelerator Programme (MCAP)
Amount £43,145 (GBP)
Funding ID MCAP034 
Organisation Henry Royce Institute 
Sector Academic/University
Country United Kingdom
Start 12/2022 
End 03/2023
 
Description All Things Hydrogen Webinar Series 1 (Episode 3) 
Form Of Engagement Activity A broadcast e.g. TV/radio/film/podcast (other than news/press)
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact The All Things Hydrogen Webinar Series is a collaboration between the National Subsea Centre & Robert Gordon University. Through this webinar, the purpose is to invite presenters to deliver webinar on research related to hydrogen. Through such webinar, we will delve into the essential components and collaborators required to establish a thriving global connected hydrogen related research.
Year(s) Of Engagement Activity 2022
URL https://www.youtube.com/watch?v=fhZvpAq1g00
 
Description All Things Hydrogen Webinar Series 2 (Episode 1) 
Form Of Engagement Activity A broadcast e.g. TV/radio/film/podcast (other than news/press)
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact The All Things Hydrogen Webinar Series is a collaboration between the National Subsea Centre & Robert Gordon University. Through this webinar, the purpose is to invite presenters to deliver webinar on research related to hydrogen. Through such webinar, we will delve into the essential components and collaborators required to establish a thriving global connected hydrogen related research.
Year(s) Of Engagement Activity 2023
URL https://www.youtube.com/watch?v=pYGooyr-nLc&t=1s