Forschungszentrum Jülich GmbH
The role of large-scale hydrogen deployment to carbon neutrality has gained recognition only in the recent years. As of 2022, twenty-two governments have so far announced their H2 commitments, with Germany aiming to reach 10-GW electrolysis capacity by 2030 through its H2Giga flagship project. Solid oxide cells (SOCs) are potential candidates for scale-up, attributed to their high electrical efficiencies, capacity for waste heat recovery and capability for steam-CO2 co-electrolysis among other reasons. Forschungszentrum Jülich (JÜLICH) has over 30 years’ experience in SOC stack development, and with the global shift towards electrolysis industrialization, future surges in end-of-life (EoL) SOC stacks like JÜLICH must be anticipated. JÜLICH SOC stacks comprise of repeating units of ceramic-based cells and metallic interconnects. The interconnects, consisting of coated Crofer22APU steel and soldered Ni meshes, contribute significantly in the manufacturing costs of these stacks. By exploring closed-loop recycling, particularly of interconnects, stack production costs can be potentially reduced, thereby supporting decarbonization efforts not only in the energy sector but in the steel industry as well. This study proposes and evaluates a closed-loop recycling route for Crofer22APU re-use, with a specific focus on Ni mesh removal. In this route, pre-treatment stages are first applied to selectively leach out and recover the coating elements as hydroxide precipitates. Then, the soldered Ni mesh is removed mechanically. Finally, residues of the mesh and diffused Ni are selectively dissolved in alkali sulphates. Utilizing the well-known mechanism of type II hot corrosion, the sample is covered with Alk2SO4 (Alk = Na, K) and exposed to specific P(SO3) atmospheres at elevated temperatures. Selective Ni dissolution is induced, forming an Alk2SO4-NiSO4 eutectic liquid that can be dissolved in water after cooling, leaving only Crofer22APU behind. Ni can then be recovered from the aqueous solution. Related phase stability diagrams calculated using the available databases (FTsulf, FToxid, SGTE, SGPS) in FactSage 8.2 software are also presented. Finally, dissolution tests are performed with different alkali sulphates under different atmospheric and temperature conditions to gain insights into the mechanisms and morphologies of the formed phases.
Abstract
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