Solid oxide electrolytic cell assembly (SOEC) and methods for making SOECs are provided. An exemplary method includes forming a functionalized zeolite templated carbon (ZTC). The functionalized ZTC is formed by forming a CaX zeolite, depositing carbon in the CaX zeolite using a chemical vapor deposition (CVD) process to form a carbon/zeolite composite, treating the carbon/zeolite composite with a solution including hydrofluoric acid to form a ZTC, and treating the ZTC to add catalyst sites. In the method, the functionalized ZTC is incorporated into electrodes by forming a mixture of the functionalized ZTC with a calcined solid oxide electrolyte, and calcining the mixture. The method includes forming an electrode assembly, forming the SO electrolytic cell assembly, and coupling the SO electrolytic cell assembly to a heat source.

A power-to-X system for the utilization of off-gases, includes an electrolyzer for generating hydrogen H2 and oxygen O2, a unit, connected to the electrolyzer, for processing the hydrogen H2, for removing any remaining water H2O and oxygen O2 from the generated stream of hydrogen H2, a compressor, connected to the unit for processing the hydrogen H2, for compressing the hydrogen H2, and a chemical reactor, connected to the compressor, for producing a synthesis gas consisting of hydrogen H2 and carbon dioxide CO2 that can be added. An oxy-fuel combustion system to which non-condensable off-gases from the chemical reactor and oxygen O2 from the electrolyzer can be supplied, and carbon dioxide CO2 generated during the combustion of the off-gases in the oxy-fuel combustion system can be returned to the stream of hydrogen H2 downstream of the electrolyzer via a return line.

A power-to-X system for the utilization of off-gases, includes an electrolyzer for generating hydrogen H2 and oxygen O2, a unit, connected to the electrolyzer, for processing the hydrogen H2, for removing any remaining water H2O and oxygen O2 from the generated stream of hydrogen H2, a compressor, connected to the unit for processing the hydrogen H2, for compressing the hydrogen H2, and a chemical reactor, connected to the compressor, for producing a synthesis gas consisting of hydrogen H2 and carbon dioxide CO2 that can be added. An oxy-fuel combustion system to which non-condensable off-gases from the chemical reactor and oxygen O2 from the electrolyzer can be supplied, and carbon dioxide CO2 generated during the combustion of the off-gases in the oxy-fuel combustion system can be returned to the stream of hydrogen H2 downstream of the electrolyzer via a return line.

An aspect of the present disclosure provides time and energy-efficient synthesis of catalysts for water electrolysis. An exemplary synthesis method includes dissolving amounts of Fe(NO.sub.3).sub.3.9H.sub.2O and Na.sub.2S.sub.2O.sub.3.5H.sub.2O in deionized water at ambient temperature to form a solution, placing Ni foam into the solution where the Ni foam serves as a substrate and a Ni source for growth of sulfur-doped (Ni,Fe)OOH (S—(Ni,Fe)OOH) catalysts, leaving the Ni foam in the solution at ambient temperature for a duration between one minute and five minutes to provide a treated foam where the S—(Ni,Fe)OOH catalysts grow on the substrate during the duration, and removing the treated foam from the solution after the duration.

An aspect of the present disclosure provides time and energy-efficient synthesis of catalysts for water electrolysis. An exemplary synthesis method includes dissolving amounts of Fe(NO.sub.3).sub.3.9H.sub.2O and Na.sub.2S.sub.2O.sub.3.5H.sub.2O in deionized water at ambient temperature to form a solution, placing Ni foam into the solution where the Ni foam serves as a substrate and a Ni source for growth of sulfur-doped (Ni,Fe)OOH (S—(Ni,Fe)OOH) catalysts, leaving the Ni foam in the solution at ambient temperature for a duration between one minute and five minutes to provide a treated foam where the S—(Ni,Fe)OOH catalysts grow on the substrate during the duration, and removing the treated foam from the solution after the duration.

A coated electrode assembly (CEA) comprising: i) a gas diffusion layer (GDE); and ii) a coating. The GDE comprises a gas diffusion layer (GDL) and a catalyst layer. The catalyst layer is disposed between the coating and the GDL. The catalyst layer comprises a hydrophobic polymer and/or an ionomeric polymer and the coating comprises a hydrophobic polymer and/or an ionomeric polymer. A method for making a CEA is provided. The CEA may have improved performance and stability compared to a membrane electrode assembly (MEA).

A coated electrode assembly (CEA) comprising: i) a gas diffusion layer (GDE); and ii) a coating. The GDE comprises a gas diffusion layer (GDL) and a catalyst layer. The catalyst layer is disposed between the coating and the GDL. The catalyst layer comprises a hydrophobic polymer and/or an ionomeric polymer and the coating comprises a hydrophobic polymer and/or an ionomeric polymer. A method for making a CEA is provided. The CEA may have improved performance and stability compared to a membrane electrode assembly (MEA).

The present invention provides: a heat generation method that makes the first use of the ionic vacancies that are a by-product of an electrochemical reaction and have conventionally been left unreacted; and a device for implementing the same. The present invention pertains to: a heat generation method characterized by comprising colliding, in an electrochemical reaction that proceeds in an electrolysis cell, ionic vacancies having a positive charge generated at an anode and ionic vacancies having a negative charge generated at a cathode; and a heat generation device characterized by being equipped with an electrolysis cell provided with an anode and a cathode and an electrolyte solution accommodated within the electrolysis cell, and by generating heat by colliding ionic vacancies of opposite signs generated by causing the electrochemical reaction to proceed in the electrolysis cell via the anode and the cathode.

The present invention provides: a heat generation method that makes the first use of the ionic vacancies that are a by-product of an electrochemical reaction and have conventionally been left unreacted; and a device for implementing the same. The present invention pertains to: a heat generation method characterized by comprising colliding, in an electrochemical reaction that proceeds in an electrolysis cell, ionic vacancies having a positive charge generated at an anode and ionic vacancies having a negative charge generated at a cathode; and a heat generation device characterized by being equipped with an electrolysis cell provided with an anode and a cathode and an electrolyte solution accommodated within the electrolysis cell, and by generating heat by colliding ionic vacancies of opposite signs generated by causing the electrochemical reaction to proceed in the electrolysis cell via the anode and the cathode.

An electrolyzer stack is configured for high-speed manufacturing and assembly of a plurality of scalable electrolysis cells. Each cell comprises a plurality of water windows configured to maintain a pressure loss, temperature rise and/or oxygen outlet volume fraction below predetermined thresholds. Repeating components of the cells are configured based on a desired roll web width for production and a stack compression system is configured to enable a variable quantity and variable area of said repeating cells in a single stack. A high-speed manufacturing system is configured to produce scalable cells and assemble scalable stacks at rates in excess of 1,000 MW-class stacks per year.