Researchers in Switzerland and France are working on a new technology aimed at lowering the cost of green hydrogen production, a development that could strengthen the global clean energy and bioenergy transition.
Scientists from Swiss National Science Foundation-supported projects at Empa are collaborating with French research institutes to develop more affordable materials for electrolysers, the devices used to produce hydrogen from water using electricity generated from renewable energy sources, Newswire reported.
Green hydrogen is considered an important part of the transition away from fossil fuels because it produces only water when used as fuel. However, most hydrogen produced globally still comes from fossil sources such as natural gas, mainly because green hydrogen remains expensive to manufacture.
According to the researchers, one of the main reasons for the high cost is the expensive materials required inside electrolysers, particularly in proton-exchange membrane water electrolysis (PEMWE) systems.
PEMWE technology is considered efficient and suitable for renewable energy systems, but the highly corrosive conditions inside the electrolyser create major technical challenges. Researchers explained that ordinary steel quickly corrodes in the acidic environment, while even tiny metal impurities can reduce performance and shorten equipment life.
To overcome this, manufacturers currently use titanium components coated with platinum, both of which are costly and difficult to process.
Empa researcher Konstantin Egorov and his team are now developing an alternative coating based on a special titanium oxide material known as highly crystalline oxygen-deficient rutile. The material offers strong corrosion resistance while maintaining good electrical conductivity.
The researchers are also replacing titanium carrier materials with steel, which is cheaper and easier to manufacture. According to Egorov, steel components could also allow engineers to create improved designs that enhance electrolyser performance.
Early results from the project have shown promising corrosion resistance. The researchers successfully coated a key electrolyser component known as the bipolar plate using a process called physical vapor deposition (PVD), a method already widely used in industry.
The coated components are being tested by research partners in France under laboratory conditions and in working electrolysers. The bipolar plate has already passed initial tests successfully.
The next phase of the project will focus on coating another important component called the porous transport layer. Researchers said coating porous materials evenly without blocking their structure remains a significant challenge.
The project is scheduled to continue until 2026, after which the researchers hope to partner with industry players to move the technology towards commercial production.
