MOLCAR Swiss Funds

The Project co-funded from the Swiss-Polish Cooperation Programme via the National Centre of Research and Development.

For more information on the programme, please visit:   https://www.programszwajcarski.gov.pl/en

Name of the project: Modular system based on Molten Carbonate Electrolysis supported by solar energy designed for synthetic fuels generation

Acronym: MOLCAR

Project application number: SPPW/MOLCAR/0087/2024

Call number: SPPW/Call2024/18/2025

Entities of the Project Consortium:

• Programme Component Operator: Warsaw University of Technology;
• Programme Component Partners: Ecole Polytechnique Federale de Lausanne (EPFL) https://www.epfl.ch/en/  - Laboratory of Renewable Energy Science and Engineering https://lrese.epfl.ch ; Fuel Cell Poland https://fuelcell.pl

Project leader: Prof. Jarosław Milewski

The total cost of Project implementation: 4 634 194,82 PLN

The total amount of eligible costs: 4 634 194,82 PLN

The amount of funding in the form of payment from the budget of European funds: 3 653 875,03 PLN

Co-financing from the State budget (targeted grant): 778 287,79 PLN

Dates of eligibility: 1.7.2025-30.6.2028

Project duration: 36 months (starting month: July 2025)

Project description:

The project focuses on research and development aimed at constructing a solar energy system based on molten carbonate electrolysis (MCE) operating with biomass flue gas streams to produce synthetic fuels. This unit can be a key component of energy storage systems that realize the power-to-liquid concept. In such systems, excess electricity from renewable sources (solar) is used to generate synthetic fuels. Additionally, MCE aids at increasing the operational flexibility of biomass-based power units, especially considering the expected frequent shutdowns of centrally disposed units. Molten carbonate electrolysis offers several advantages over alkaline and PEM electrolysis installations which have an established position in the market.

The project focuses on the concept development, design, construction, and experimental studies of a prototype 12 kW-class system with an MCE stack, which exhibits carbon capture in excess of 90% for biomass-fired power in MCE (with hydrogen generation above 100% electric efficiency), resulting in e-fuel costs being approximately 30% lower. The MCE stack has a modular design, making it possible to integrate several of these units to build larger e-fuel systems. Solar energy will be directly used for the production of synthetic fuels through a high temperature molten salts loop, allowing integration into the MCE stack construction. This results in higher flexibility and security of energy supply. As a result, e-fuels become energy storage systems. The importance of this aspect is particularly notable for large-scale biomass boilers. MCE-based systems are constructed, unlike other fuel cells that operate only on a sub-kW scale.

The project is structured into 6 interdependent WPs, each logically sequenced to ensure progress among the tasks.

WP1 focuses on materials development to enhance the performance and durability of CSP and MCE systems. Tasks include selecting and testing heat carriers, identifying the thermal behaviour of the MCE, and determining heat management strategies. Deliverables will include reports on heat carrier selection, thermal behaviour analysis, and heat management strategies, with a timeline from M1 to M12.

WP2 aims at developing and validating numerical models to optimize CSP and MCE system designs. This involves developing a CSP and MCE model. Additionally, design optimization will achieve less than 5% error. Deliverables are detailed reports on each model and design optimization, running from M2 to M18.

WP3 is dedicated to developing a 12 kW MCE stack for efficient H2 production. Tasks include cell manufacturing and assembly, heat exchangers manufacturing and integration, BoP manufacturing and test runs to validate performance. Deliverables include reports on manufacturing and performance tests, spanning from M6 to M24.

WP4 involves industrial research and testing to validate the system’s long-term performance and reliability. This includes short to long run tests to ensure system durability and reliability. Additionally, the efficiency of the system with a 30% solar feed and 100% electricity-to-hydrogen conversion will be evaluated. Deliverables include reports on tests with the timeline from M12 to M30.

WP5 focuses on scaling up the technology for commercial production. This involves developing scalable manufacturing processes for CSP and MCE systems, conducting pilot scale production to validate scalability, and addressing scalability issues while refining manufacturing processes. Deliverables include reports on scalable manufacturing processes, pilot production, and scalability analysis, scheduled from M18 to M36.

WP6 prepares technology for market entry, encompassing business planning and regulatory compliance. Deliverables comprise of market analysis reports, patent reports, planned from M24 to M36.

The interdependencies among the WPs ensure a smooth transition and integration of findings. WP1 provides critical data on material properties and thermal behaviour, feeding into the models developed in WP2. These models guide the development and testing in WP3, whose findings on stack performance and integration inform the industrial-scale testing protocols in WP4. Insights from WP4’s long-term performance tests refine the scalability efforts in WP5, and the outcomes of WP5 are crucial for market entry preparations in WP6.

Communication Objectives of the Project: The primary objectives are to raise awareness about the project's goals, progress, and outcomes; engage stakeholders and the public; and promote the benefits of the Research and Innovation Programme. Measurable targets include reaching a wide audience through online and offline channels, generating media coverage, and achieving high attendance at events. Target Audience: The target audience includes national, regional, and local stakeholders such as industry partners, policymakers, energy providers, researchers, and the general public. Strategy and Content: The communication strategy will involve a mix of activities and tools designed to maximize impact.