[ case study ]
Fig. 2. 3D visualisation of the SOE-based VETNI system
The solid oxide electrolyser was integrated into the industrial infrastructure at the refinery, creating a complete system for producing hydrogen from steam, followed by compression and storage. Notably, the solutions applied in Jasło delivered the expected efficiency gains: the VETNI installation requires only 42 kWh to produce 1 kg of hydrogen, compared to 55 – 70 kWh / kg for commercially available low-temperature electrolysers( alkaline and PEM). The 30 kWclass system achieved this result with further reductions expected – potentially below 39 kWh / kg – in larger systems. Importantly, this efficiency was achieved by a first-of-its-kind unit, indicating scope for further optimisation.
In addition to reduced electricity consumption, a new generation of air electrodes with limited cobalt content was developed and tested in an industrial environment. The gradual elimination of cobalt from SOE components is a key focus in the development of this technology and is currently being pursued by the Polish research team involved in the VETNI project. Reducing cobalt use lowers material costs while maintaining or even improving performance and durability. This is crucial to reducing dependence on scarce resources in the hydrogen value chain.
During the VETNI project, numerous process parameters were recorded, processed, and analysed – including current-voltage profiles, gas characteristics, and the overall efficiency of both the electrolyser and the complete system. The hydrogen production process was also studied under varying electrical loads and dynamically changing operating points.
SOE stack – the heart of the electrolysis system
A stack of solid oxide electrochemical cells( SOC) is an advanced device made of ceramic cells, steel elements with protective layers, and seals. The right selection of components is essential to ensure long-term, failure-free operation of the entire system. In particular, the ratio of thermal expansion of materials must be carefully matched to enable the connection of ceramic and metal elements of the device, and the steel elements – coated with special layers to prevent degradation – must be able to conduct electricity and serve as interconnectors between individual cells in the stack.
The manufacturing techniques of SOC stack components used in this project include a number of innovative methods developed at the Center
24 Hydrogen Tech World | Issue 22 | June 2025