GREENSEAL. New Sealant Manufacturing Processes Using Functional Printing For High-Performance Electrolyzers

The GREENSEAL project aims to innovate in the production of seals for electrolyzer stacks, which are essential to ensure tightness and proper operation under extreme conditions. To achieve this, the project will explore the use of functional printing technologies, enabling more efficient seal application, preventing leaks, and simplifying assembly. Additionally, this technology offers advantages such as application on complex component designs and the integration of advanced sensors to enhance system control and monitoring. The project will focus on developing seals for two distinct electrolysis technologies: alkaline electrolysis (AEL), a well-established technology, and solid oxide electrolysis (SOEL), an emerging but highly promising alternative.

Framed within the “Green Energy Industry” priority, GREENSEAL is a joint initiative between the Hydrogen Area of CENER, specializing in electrochemical hydrogen production technologies, and Mondragon Components Competence Center(mc3), an expert in functional printing. This project will enhance the competitiveness of electrolyzers by reducing costs and improving seal reliability, facilitating their integration into industrial hydrogen production. Furthermore, it reinforces the commitment to technological innovation in renewable energy, aligning with the goals of the European Green Deal and the European Commission’s hydrogen strategy, which recognizes hydrogen as a key driver for industrial decarbonization and the transition to a clean and sustainable energy system.

CENER plays a fundamental role in this project, leading several critical activities related to the development, validation, and industrial viability of sealants for electrolyzers. It is responsible for designing and implementing a dedicated test bench for AEL sealants, leveraging its facilities and expertise to ensure reliable performance. Additionally, CENER conducts microstructural and compositional analysis of AEL sealants and takes the lead in the modification of interconnectors for SOEL electrolyzers. In the field of SOEL technology, it oversees sealant validation, performing thermal stability tests, electrochemical characterization, and post-drying treatments to refine material properties. Beyond the technical aspects, CENER contributes to the techno-economic analysis, providing insights into market potential, cost comparisons, and production scaling strategies. As the general coordinator, it ensures the project’s smooth execution, risk management, and scientific quality validation while acting as the main liaison with the Government of Navarra. Lastly, it plays a key role in communication and dissemination, working to maximize the project’s visibility and commercial impact.