New process to make hydrogen production cheaper

28.05.2025

Source: E & M powernews

A pilot plant for SOEC stacks has gone into operation in Arnstadt in Thuringia. It is intended to advance the industrial use of high-temperature electrolysis for green hydrogen.

Great expectations are being placed on hydrogen as an energy source. However, its production is still considered expensive. A pilot project involving industry and science now aims to change this. The thyssenkrupp subsidiary and the Fraunhofer Institute for Ceramic Technologies and Systems (IKTS) opened a pilot production facility for electrolysis stacks on May 27. The plant is the first to produce stacks for electrolysers based on solid oxide electrolysis cells (SOEC). The partners want to use it to advance the technology's readiness for series production.

Initially, production is to start with small quantities. According to the partners, the planned annual output is 8 MW. The aim is to gain experience for subsequent industrial series production.

SOEC technology uses high temperatures of 900 degrees Celsius to split water vapor into hydrogen (H2) and oxygen (O2). According to the partners, this reduces the amount of electricity required compared to other hydrogen production processes. According to Thyssenkrupp Nucera, energy savings of 20 to 30 percent can be achieved, particularly in industrial sectors with waste heat, such as the steel or cement industry.

The ceramic cells are assembled into stacks in the Arnstadt plant. They consist of an oxygen-conducting electrolyte, two electrodes and metallic connecting elements made of chrome and iron. The construction is designed for longevity and automated production. Few components and a compact form should reduce manufacturing costs later on.

Fraunhofer IKTS, based in Dresden, developed the technology and planned the pilot plant. Thyssenkrupp Nucera, headquartered in Dortmund, is contributing its industrial experience and existing electrolysis portfolio to the pilot project. To date, the company has mainly offered systems based on alkaline water electrolysis (AWE). The SOEC is intended to supplement the range with a variant for energy-intensive industrial processes.

"We see high-temperature electrolysis as a key element for a climate-friendly energy supply," explained Werner Ponikwar, CEO of Thyssenkrupp Nucera. The technology should play a key role in the hydrogen economy in the future.

Professor Alexander Michaelis, Head of Fraunhofer IKTS, also emphasized the strategic advantages of the new production process: "By using waste heat or directly producing synthesis gas from water and CO2, companies can significantly increase their efficiency."

Precursors for green fuels can also be produced

In addition to hydrogen, synthesis gas can also be produced using SOEC technology. Industrial CO2 is combined with hydrogen for this purpose. The result is precursors for green fuels and chemical base materials. This coupling of processes is considered particularly sustainable. In March 2024, the two partners signed a contract to seal their strategic collaboration (we reported). The new plant marks the start of the next project phase. The data obtained from the pilot operation will be incorporated into the planning of large-scale, fully automated production.

Author: Davina Spohn