Green hydrogen production, no scarce resources needed
The EU-funded HYScale(opens in new window) project is redefining green hydrogen production. It has successfully developed high-performance materials that reduce reliance on critical raw materials (CRMs) and synthetic chemicals called per- and polyfluoroalkyl substances (PFASs). Green hydrogen is a sustainable and versatile energy source that can play a crucial role in decarbonising Europe’s energy-intensive sectors. However, obstacles such as cost, durability, efficiency and resource scarcity need to be overcome before it can be widely adopted. HYScale has taken up this challenge. As an article(opens in new window) posted on the project’s website describes: “HYScale is … upscaling innovative high-performance materials that reduce dependency on scarce resources, without compromising on performance or efficiency.” The project has replaced CRMs and PFASs traditionally used in anion exchange membrane (AEM) water electrolysers, a technology employed in hydrogen production. Instead, it is advancing a more economical and environmentally friendly alternative – the first single stack 100 kW AEM electrolyser prototype. Tests have shown that HYScale’s newly developed materials can be scaled up without compromising performance. “Large-scale applications are now delivering results that align with those achieved in small-scale single-cell laboratory tests, a crucial milestone on the path to real-world implementation,” reports the article. This brings the project “one step closer to integrating the stack into a fully functional electrolyser system.” HYScale is aiming for a capital expenditure of EUR 400/kW and is making strides towards industrial validation.
Getting to this point
To scale up to a full electrolyser system, the HYScale team first had to optimise individual cell components. They set about refining catalysts, membranes and porous transport layers in small-area cells to ensure the efficiency, durability and long-term operation of each component. Project partner Italian National Research Council (CNR) investigated the influence of the substrate used for the electrode. They also analysed the type of porous transport layer, designed and manufactured by Belgian project partner Bekaert. Project coordinator CENmat provided catalyst-coated substrates using high-performance CRM-free catalysts. CNR and German partner DLR performed extensive tests to assess the components’ performance and stability. To meet scalability targets, the project team also developed a large-area cell. The design incorporates specialised solutions for the frames, sealing and transport layers, and was optimised to minimise machining steps. A flow field-free design was also adopted. CNR researcher Nicola Briguglio explains: “The decision … was driven by the need to simplify the architecture of the AEM short stack and reduce manufacturing complexity. Additionally, eliminating the flow field reduces the overall thickness of the stack and facilitates a more compact and lightweight design, which is beneficial for system integration and scale-up.” Testing is now underway as part of the short-stack phase. HYScale (HYSCALE – ECONOMIC GREEN HYDROGEN PRODUCTION AT SCALE VIA A NOVEL, CRITICAL RAW MATERIAL FREE, HIGHLY EFFICIENT AND LOW-CAPEX ADVANCED ALKALINE MEMBRANE WATER ELECTROLYSIS TECHNOLOGY) is working towards integrating the stack into a fully functional electrolyser system, laying the foundations for more efficient electrolyser systems that bring Europe closer to its climate goals. For more information, please see: HYScale project website(opens in new window)
