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Development of seal-less proton-exchange-membrane (PEM) water electrolysers within HORIZON-JU-CLEANH2-2025-01-01

Summary

Closed for EoI
Profile Type
  • Research & Development Request
POD Reference
RDRDE20250305018
Term of Validity
5 March 2025 - 5 March 2026
Company's Country
  • Germany
Type of partnership
  • Research and development cooperation agreement
Targeted Countries
  • All countries
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General information

Short Summary
A German research institute has developed a bipolar plate made of thermoplastic & graphite compounds and weldable membrane-electrode assemblies that allow for the development of welded electrolyser stacks. Welded seams can lead to tighter stacks, which facilitates the mass production of electrolytic cells. The aim is to bring the technology to TRL 6. Sought are partners with expertise in porous transport layers and polymers to submit a project to Call HORIZON-JU-CLEANH2-2025-01-01.
Full Description
A German research institute and at least one more partner from Germany want to form a consortium to submit a project to Call HORIZON-JU-CLEANH2-2025-01-01. International partners, including a coordinator, are sought.

Reducing the cost of PEM water electrolyzers is crucial for making green hydrogen economically viable. This can be achieved by cheaper catalysts as well as bipolar plates. Recent studies have shown that uncoated carbon bipolar plates (C-BPs) are an alternative to titanium bipolar plates (Ti-BPs). While C-BPs showed higher corrosion rates in accelerated ex-situ tests, they demonstrated low degradation rates and stability during long-term operation in a Proton Exchange Membrane Electrolyzer. The findings suggest that C-BPs could be a cost-effective option for electrolyzers, challenging previous expectations about their corrosion behavior.

A German institute for applied research aims to industrialize the production of PEM electrolyzers. It focuses on optimizing manufacturing processes and equipment to mass-produce electrolyzers and their components, particularly by developing production methods for electrolyzer stacks. In a recent project it has explored cost-effective solutions, including the use of thermoplastic cell components, to simplify and reduce the cost of manufacturing while ensuring high efficiency for large-scale hydrogen production.

In this context, it has developed a bipolar plate made of thermoplastic & graphite compounds and weldable membrane-electrode assemblies that allow for the development of welded electrolyser stacks. The stack design is to be manufactured exclusively from thermoplastic cell components (bipolar foils, frame elements, membrane electrode unit) and using conventional joining processes (laser or ultrasonic welding). This means that hundreds of sealing surfaces in the electrolysis stack can be replaced by robust weld seams, facilitating the mass production of electrolyser cells.
The goal is to bring the technology to TRL 6 by submitting a proposal to Call HORIZON-JU-CLEANH2-2025-01-01. Goal of the project is to develop seal-less proton-exchange-membrane (PEM) water electrolysers.

The German research institute and one other German partner are looking for international partners (companies or research institutions) that can can complement the consortium. One of the partners should be willing to take on the role of project coordinator. Sought are contributions in the field of porous transport layers (multilayer PTL, microporous layers, advanced coatings with e.g. carbon) and in the field of plastics technology, especially the joining of plastics. The goal is to submit a proposal in HORIZON-JU-CLEANH2-2025-01-01.

Possible tasks and roles in the project:

• Porous transport layers:

- development of multi-layer porous transport layers (i.e., expanded metals, made from Ti or coated stainless-steel)
- development of micro-porous layers for Ti-PTLs
- Coating of porous transport layers with carbon and / or PGM to enhance contact interface

• high throughput welding of polymer components

- development of welding methods for the cell manufacturing (i.e., ultrasonic, laser-welding)
- Polymers include PP (Gen1) or high-performance polymers for Gen2 such as PPS, PES, PSU, or PEI
- Focus on high-Quality weld seams while improving the production rate

• Project coordination

- coordination of dissemination tasks
- Data management activities
- General project coordination

The call deadline is April 23rd, 2024, therefore the EOI (expressions of interest) deadline is set for March 28th, 2024.

Also sought are partners that would like to acquire a license of the technology.
Advantages and Innovations
• sealing surfaces in the electrolysis stack can be replaced by robust weld seams, facilitating the mass production of electrolyser cells
• reduced stack cost by up to 30 %
• reduced membrane degradation due to reduced metal content in the electrolyser cell (no metal leaching from bipolar plate)
Technical Specification or Expertise Sought
Sought are contributions in the field of porous transport layers (multilayer PTL, microporous layers, advanced coatings with e.g. carbon) and in the field of plastics technology, especially the joining of plastics / welding of polymer components.
Stage of Development
  • Under development
Sustainable Development Goals
  • Goal 7: Affordable and Clean Energy
IPR status
  • IPR granted

Partner Sought

Expected Role of a Partner
• Porous transport layers:
- development of multi-layer porous transport layers (i.e., expanded metals, made from Ti or coated stainless-steel)
- development of micro-porous layers for Ti-PTLs
- Coating of porous transport layers with carbon and / or PGM to enhance contact interface

• high throughput welding of polymer components
- development of welding methods for the cell manufacturing (i.e., ultrasonic, laser-welding)
- Polymers include PP (Gen1) or high-performance polymers for Gen2 such as PPS, PES, PSU, or PEI
- Focus on high-Quality weld seams while improving the production rate

• Project coordination
- coordination of dissemination tasks
- Data management activities
- General project coordination
Type and Size of Partner
  • Other
  • Big company
  • University
  • SME 50 - 249
  • SME 11-49
  • SME <=10
  • R&D Institution
Type of partnership
  • Research and development cooperation agreement

Call details

Framework program
  • Horizon Europe
Call title and identifier
HORIZON-JU-CLEANH2-2025-01-01
Coordinator required
Yes
Deadline for EoI
Deadline of the call
Web link to the call
https://ec.europa.eu/info/funding-tenders/opportunities/portal/screen/opportuni…

Dissemination

Technology keywords
  • 02002002 - Coatings
  • 04002012 - Other energy related machinery
  • 02007014 - Plastics, Polymers
  • 04002002 - Hydrogen production
  • 02002008 - Jointing (soldering, welding, sticking)
Market keywords
  • 06003003 - Wind energy
  • 06007001 - Other energy production
  • 06010003 - Energy for Industry
  • 06003001 - Solar/thermal energy
  • 06002004 - Hydro-electric
Sector Groups Involved
  • Renewable Energy
  • Energy-Intensive Industries
  • Electronics
  • Mobility - Transport - Automotive
Targeted countries
  • All countries