This project aims to establish a TRL6 CO₂ electrolysis plant and testing facility, a first of its kind in Flanders, to evaluate electrolyzer technologies under industrially relevant conditions such as flue gas feeds and fluctuating high-power loads. The absence of such infrastructure in the region has limited progress in advancing CO₂ electrolysis technology, and this project seeks to address that gap. ELECTRA will create a modular, pilot-scale electrolyzer designed to meet key requirements, such as enabling direct electrochemical conversion of CO₂ into gaseous or liquid products at elevated temperatures (up to 90°C) and pressures (up to 25 bar). The system will support different configurations, including zero-gap and flow-by designs, with a flexible setup that allows varying the number of cells (up to 80) and their sizes (up to 1 m²). Additionally, it will feature diverse electrode types, such as plates, meshes, and gas diffusion electrodes, and will be equipped with a fully automated control and monitoring system to ensure safe and reliable operation, including emergency shutdowns.

The facility will evaluate electrolyzer components under real-world conditions, aiming for high productivity (kg h^-1 scale), sustained operation (over 1000 hours), and efficient performance with impure CO₂ streams during intermittent operations. This evaluation is crucial in determining whether the available reactor components and configurations are suitable for large-scale applications, addressing technical challenges, and improving the economic competitiveness of CO₂ electrolysis technology. The project has several objectives, including the development of a pilot-scale CO₂ electrolysis stack for CO production under industrially relevant conditions (e.g., >300 mA cm^-2 , 60°C, electrode area >1 m² ) using CO₂ streams with impurities like O₂, SO_x, and NO_x. Another key goal is to extend electrolyzer performance to over 1000 hours of operation, improve CO₂ conversion to more than 30% per pass, and mitigate failure mechanisms through optimized reactor and component designs. The project also aims to assess and compile a list of the most suitable commercially available electrolyzer components for stable operation and develop strategies for improving them to achieve TRL 7 in future collaborations with industry.

The successful completion of this project will create a unique test facility, currently lacking in the field, bridging the gap between academia and industry and bringing CO₂ electrolysis closer to practical implementation. Once completed, the facility is expected to be integrated into the BlueApp valorisation hub at the University of Antwerp, making it accessible to third parties for testing components.