MERIT

Mechanically robust SOEC stacks for flexible system integration

Project area

Resource procurement (Input)
Fuel production
Refining and upgrading
Storage
Transport
Distribution
Utilisation
Post-treatment and recycling
Safety and standardisation
Systems integration / sector coupling
Community work and stakeholder involvement
Structural frameworks, regulation, and markets

All projects in the MissionGreenFuels project portfolio contribute to the green transition across the green fuels value chain and cross-cutting themes. The highlighted icons indicate the area this project contributes to. Click on the icons to lean more.

Project description

Electrolysis is a key component in the Power-to-X value chain. A critical requirement for electrolysers is robustness under dynamic operation and flexibility for system integration. Solid oxide electrolysis technology is known for its high efficiency and independence from precious metal elements. Ensuring mechanical durability throughout years of dynamic operation remains, however, a challenge at the stack level.Dynamic operation induces thermo-mechanical stresses due to mismatches in the coefficients of thermal expansion among stack components, increasing the risk of cracking and failure, especially in the sealants and adjacent components. Merit aims to understand and enhance the mechanical behaviour of sealings under dynamic operation, thereby improving the solid oxide electrolysis stack durability and enhancing the system integrability of the technology.

Project facts

Total budget of the project including co-financing
0 million DKK

Project start

January 2026

Project status

Active

Funding pool

Pool 3 Solutions

Inflection point

Technology clarification and demonstration

Value chain and theme

Fuel production

Project objectives

Develop methodologies to experimentally simulate dynamic operational conditions and evaluate the mechanical behaviour of sealings, focusing on various glass-ceramic sealings and interconnect coatings to identify critical factors affecting durability.

Project partners

P4
Topsoe_logo.svg

Impact & outcome

 

The project aims to achieve:

  • A 50% enhancement in the fracture toughness of sealings.
  • A 30% increase in thermal cycles annually.

 

Project contact

Peyman Khajavi

Peyman Khajavi

DTU Energy
Assistant Professor

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The green fuel value chain and cross-cutting themes

Resource procurement (Input)
Identification, sourcing, and supply of biomass, CO₂, green electricity, or waste materials (feedstock) used as input for fuel production.
Fuel production
Processes that transform the basic energy resources into primary energy carriers (e.g. hydrogen).
Refining and upgrading
Processes that purify, enhance or synthesize fuels/hydrogen to meet specific quality and performance standards.
Storage
Technologies and systems for containing larger quantities of fuels (methanol, ammonia, hydrogen, SAF) over time.
Transport
Logistics and infrastructure for moving fuels from production to consumption sites, covering pipelines, trucks, ships, etc.
Distribution
End-point delivery for supplying fuels to users (e.g. fuelling stations, industrial supply lines, on-site storage).
Utilisation
Application of the fuels in end-use sectors such as heavy transport, aviation, shipping, and power generation in industry. The end-user is responsible for sourcing of energy/fuels, as well as new technologies and assets capable of utilising these, often with the purpose of reducing GHG emissions and environmental impact. Furthermore, end-users are also responsible for meeting new regulatory requirements and handling all technical and commercial risks related to the application of new and more expensive energy, following the energy transition. Utilisation includes extensive field testing of new technologies and fuels to overcome technical challenges and test production and supply chain infrastructure.
Post-treatment and recycling
Handling of byproducts, residues or emissions, and processes for material recovery or environmental management.
Safety and standardisation
Development and application of safety protocols, technical standards and certifications to ensure secure handling and interoperability.
Systems integration / sector coupling
Linking fuel production and use with other energy systems and sectors (e.g. power-to-x, grid balancing, industrial symbiosis) to optimise efficiency and resilience. Primarily an analytical focus.
Community work and stakeholder involvement
Engagement of local actors, citizens and industry stakeholders to support implementation, acceptability and social sustainability.
Structural frameworks, regulation, and markets
Analysis, development and test of policy, regulatory structures, incentive mechanisms, and market models to enable deployment and scaling.