Endure in detail
The ENDURE project is a pioneering initiative designed to significantly enhance the performance and lifespan of alkaline electrolysers, a vital technology for producing green hydrogen. The project aims to achieve this by developing novel 3D-structured porous transport electrodes (PTEs) that improve both the electrochemical kinetics and mass transport within electrolysis cells. By replacing costly platinum-group metals (PGMs) with more sustainable materials and incorporating advanced simulation techniques like computational fluid dynamics (CFD), ENDURE is set to deliver high-performing, cost-effective solutions to the hydrogen industry. With a structured work plan, the project tackles the challenges of scaling up these innovations from the lab to real-world applications.
Establishing Methods and Baseline
The groundwork for the entire project is laid by establishing key performance benchmarks for alkaline electrolysers. A 10 kW electrolysis stack equipped with pre-commercial nickel foam electrodes undergoes rigorous testing to define a baseline performance. Additionally, harmonised testing protocols are used across the different stages of the project. These protocols ensure consistent and reliable performance assessments, providing a reference point for future innovations developed in later development phases.
Electrode Development and Scale-Up
The ENDURE project focuses on the development of innovative porous transport electrodes (PTEs). These electrodes, designed using advanced 3D structures, aim to improve the catalytic surface area, boost gas bubble removal, and enhance overall cell efficiency. The production of these PTEs will be scaled up from the lab to industrially relevant sizes, with the goal of creating electrodes that offer both high performance and long-term durability without the need for PGMs. These innovations will ultimately lead to the creation of electrodes capable of operating at higher current densities while maintaining efficiency.
Cell and Stack Development
Building on the electrode development and scale-up phase, these advancements will be integrated into a fully functional electrolysis stack. This includes optimising the flow fields, gaskets, and other stack components to ensure the electrodes operate under ideal conditions. A prototype stack of 1000 cm² cells will be mounted, incorporating PTEs and exploring solutions to minimise gas crossover and improve the structural stability of the stack under high pressure and temperature conditions. This stage is critical in demonstrating that the lab-scale developments can be applied to real-world hydrogen production systems.
Testing and Validation
Once the prototype stacks is developed, its performance will be rigorously tested and validated. Long-term durability tests will be conducted on the stacks, monitoring for degradation and other performance-limiting factors. By simulating real-world operating conditions, these tests ensure that the innovations made meet industry standards for reliability and efficiency. In addition to performance testing, post-mortem analyses will be conducted on used components to understand the degradation mechanisms and further refine future designs.
​