EngD Position in seals for green hydrogen production

The Department Mechanics of Solids, Surfaces & Systems (MS3), part of the faculty of Engineering Technology (ET) is currently seeking an EngD candidate developing advanced sealing solutions for electrolyzer stacks, crucial components in green hydrogen production.

Hydrogen, a key player in the clean energy transition, requires efficient and safe production methods. Electrolysers, which split water into hydrogen and oxygen, rely heavily on effective sealing to contain (and separate) electrolytes, gases, and water within the system. However, current design models often overlook the microscopic details that significantly impact seal performance.

A major challenge is "roughness-induced leakage," where the microscopic surface roughness of materials creates pathways, called percolation channels, for fluids and gases to permeate through seals. This occurs even when seals appear macroscopically intact. This project aims to address this issue by developing tools and guidelines that account for surface roughness during the design process.

Furthermore, the sealing components must be resistant to degradation, as electrolyser stacks should produce hydrogen for a long time. Too frequent safety inspections are very costly, both monetary and laborious, and proper material and design selection for sealing is therefore a crucial component of the initial design phase of an electrolyser stack.

The goal is to improve the long-term performance and reliability of electrolyzer stacks by preventing leaks and ensuring the safe containment of hydrogen. Improved seal design will also minimize the need for frequent and costly inspections, contributing to the overall economic viability of green hydrogen production. By addressing the microscopic details of seal performance, this project aims to enhance the efficiency and durability of electrolysers, ultimately advancing the widespread adoption of green hydrogen as a sustainable energy source.