Boosting efficiency and lifetime in solid oxide planar
KEY INNOVATION
AC:DC mode
OPERATING CONDITIONS
Temperature | Current density | Cell area
700 °C >1A/cm² 80 cm²
DEGRADATION TARGET
−40% vs conventional SOEL
48moNTHS.
2026 — 2029
Discover Innovation Behind ThunderStack
At the heart of ThunderStack is the exploration of innovative AC:DC operational modes for high-temperature solid oxide electrolysers to enhance electrochemical performance and reduce degradation. Together with advanced materials, scalable manufacturing, balance-of-plant simplification, and recyclability, this innovation aims to deliver the next generation of solid oxide electrolysers with higher efficiency, improved durability, reduced dependence on critical raw materials, and lower levelized cost of hydrogen (LCOH) for large-scale green hydrogen production.
Objective
The objective of ThunderStack is to develop next-generation solid oxide electrolyser stacks with significantly improved efficiency, durability, and sustainability for large-scale green hydrogen production. The project combines advanced materials, innovative manufacturing, balance-of-plant integration, and smart monitoring to reduce degradation, lower critical raw material use, and accelerate the commercialization of high-performance electrolysis technologies.
METHODOLOGY
From powder to validated stack, six coordinated work streams running over 48 months with 6 European partners contributing complementary expertise
01. Material Processing
Synthesis and characterisation of electrode and electrolyte materials tuned for AC:DC operation and improved high-temperature durability.
04.System Integration
Balance of Plant design — thermal management, power electronics, and gas handling adapted for pulsed AC:DC operation at industrial scale.
02.Cell Manufacturing
Fabrication of single cells with 80 cm² industrial geometry and systematic sudy of processing routes and their impact on long-term performance
05. LONG-DURATION TESTING
Performance and degradation testing at cell and stack level with life-cycle assessment and full sustainability analysis across all partners.
03. STACK DEVELOPMENT
Assembly and optimisation of short stacks including sealing, interconnect engineering, and contact-layer design adapted for AC:DC suitability.
06.VALIDATION
Operation under industrially relevant conditions with re-engineering feedback guiding future system design and commercial pathway definition.
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