Electrochemical system integration and scale-up
Electrochemical technologies are key to the transition towards a low-carbon and circular industry. VITO combines advanced pilot infrastructure with expertise in system integration, process optimisation and industrial validation for applications including green hydrogen, CO₂ utilisation, metal recovery and process electrification. Our activities support the scale-up and industrial deployment of electrochemical systems under relevant operating conditions.
Upscaling and integrating electrochemical processes and technology
VITO specialises in the integration of electrochemical processes and technology for industrial applications. Whether you are looking to develop or upscale electrochemical systems, such as electrolysers or modules, we support the full trajectory from prototype co-development to pilot scale demonstration.
Our in-house engineering and process development expertise covers
- electrolyser stack design
- process upscaling and validation
- long-term testing
This allows for smooth integration with your existing operations and balance of plant requirements.
Possible applications
Our electrochemical system integration platform supports a range of key industrial markets, including:
- Green hydrogen (H2) production using advanced alkaline, proton exchange membrane (PEM), and anion exchange membrane (AEM) electrolysis technologies
- CO2 capture and utilisation (CCU) via CO2, CO, and bicarbonate electrolysis for sustainable carbon conversion into fuels and specialty chemicals
- Power-to-X solutions encompassing hydrogen and CCU technologies for diversified energy storage and chemical production
- Direct electrification of processes in pharmaceutical and specialty chemical manufacturing
- Recovery of precious group metals (PGMs) from end-of-life streams for recycling and resource valorisation
Why partner with VITO
- In depth expertise in electrochemical process and component development from prototype to pilot scale (TRL 6-7)
- In-house engineering capabilities in electrolyser stack, module design, balance of plant and system integration
- Advanced infrastructure for process validation, short- and long-term testing, and system durability assessment
- Tailored solutions optimised for stable industrial performance and scalability
- Experience in diverse applications including green hydrogen, CO2 electrolysis, metal recovery, and biomass conversion
- A trusted partner focused on bridging research and commercial deployment.
- Support for R&D, scale-up, and demonstration phases with a focus on industrial relevance and economic feasibility
Our electrochemical infrastructure
- ECO2FUEL: Development and scale-up of a 50 kW CO2 electrolyser stack operating under elevated pressures up to 45 bar, including balance of plant. The system converts CO2 into carbon monoxide for e-fuel production and includes continuous gas monitoring and gas recycle loops to improve conversion efficiency.
- ElCO2Syn: Demonstration of CO2 and water electroreduction to syngas at 5 kW scale using advanced silver electrodes; with scaling potential towards 100 kW and megawatt capacities for industrial applications.
- PEACOC: Pre-commercial pilot system for recovery of precious metals from automotive catalyst waste streams, integrated into a transportable container with automated operation and a production capacity of up to 10 kg of PGMs per week.
- ICO2CH: Development of a bicarbonate electrolyser stack at 5 kW for integrated CO2 capture and hydrogen production from industrial CO2 streams.
- Additional infrastructure includes H2 durability test stands with parallel cell units, supporting reliability testing of electrochemical cells under industrial conditions (parallel 2x2 cm testing of 5 samples - 10 bar, 80°C- 120°C).
