ELYntegration · Project

Industrial-Scale Hydrogen Production from Renewable Energy Using High-Pressure Electrolysis

energyTestedTRL 7

Imagine you have excess electricity from wind turbines or solar panels and nowhere to send it. This project built a big industrial machine — an electrolyser — that splits water into hydrogen using that surplus power. Think of it like a giant rechargeable battery, except instead of storing electricity, you store energy as hydrogen gas that factories and fuel stations can use later. The team tested a 250 kW prototype connected to real wind and solar plants, proving it can handle the unpredictable swings of renewable energy.

By the numbers

4.5 T H2/day

Target hydrogen production capacity at full scale

250 kW

Industrial prototype electrolyser capacity validated

1,600 mm

Cell diameter of industrial-size elementary cells

635 kW

Wind power plant used for operational testing

100 kW

Photovoltaic power plant used for operational testing

EUR 1,861,309

EU contribution to the project

6 partners

Consortium size across 4 countries

The business problem

What needed solving

Renewable energy operators lose revenue when the grid cannot absorb surplus wind or solar power, and industrial hydrogen users still depend heavily on fossil-based production methods. There is a gap in the market for cost-competitive, grid-integrated electrolysers that can handle the rapid power fluctuations of renewable sources while producing hydrogen at industrial scale.

The solution

What was built

The team built and tested a 250 kW high-pressure alkaline water electrolyser prototype (TRL 7) with industrial-size cells of 1,600 mm diameter, complete with balance of plant, power electronics, and an advanced control system. They demonstrated the real-scale stacks in an operational environment connected to a 635 kW wind plant and a 100 kW photovoltaic plant.

Audience

Who needs this

Wind and solar farm operators seeking to monetize curtailed electricity through hydrogen productionIndustrial gas companies looking for green hydrogen production equipmentOil refineries under regulatory pressure to decarbonize hydrogen feedstockChemical companies (ammonia, methanol) needing fossil-free hydrogen supplyGrid operators exploring power-to-gas for grid balancing services

Business applications

Who can put this to work

Renewable Energy Utilities

enterprise

Target: Wind or solar farm operators looking to monetize surplus electricity

If you are a renewable energy operator dealing with curtailment — losing revenue every time the grid cannot absorb your power — this project developed a 250 kW high-pressure alkaline electrolyser prototype capable of producing up to 4.5 tonnes of hydrogen per day at full scale. It was tested with a 635 kW wind plant and a 100 kW photovoltaic plant, proving it can follow rapid power fluctuations without shutting down.

Industrial Gas Supply

enterprise

Target: Hydrogen producers or industrial gas companies seeking cost-competitive production

If you are an industrial gas supplier dealing with rising natural gas costs for steam methane reforming — this project engineered a high-pressure alkaline water electrolyser designed for cost-competitive green hydrogen at scale. The prototype demonstrated industrial-size cells with 1,600 mm diameter, targeting multi-megawatt deployment that could replace fossil-based hydrogen production in your supply chain.

Chemical & Refining

enterprise

Target: Refineries or ammonia plants needing green hydrogen feedstock

If you are a refinery or chemical plant under pressure to decarbonize your hydrogen supply — this project built and validated a 250 kW electrolyser prototype at TRL 7 that integrates directly with renewable power sources. The design scales to 4.5 tonnes H2 per day, which is enough to serve as a dedicated green hydrogen feed for medium-scale industrial processes.

Frequently asked

Quick answers

What does this technology cost compared to conventional hydrogen production?

The project explicitly targeted cost-competitive hydrogen production via high-pressure alkaline electrolysis. However, the project data does not disclose specific per-kilogram hydrogen costs or capital expenditure figures. The EU contributed EUR 1,861,309 to develop and validate the 250 kW prototype across 6 partners.

Can this scale to industrial volumes?

Yes — the 250 kW prototype was explicitly designed as a stepping stone to a full-scale system producing 4.5 tonnes of hydrogen per day. The objective states that commercial deployment in large-scale demonstration projects was planned as the next step after ELYntegration's conclusion.

What is the IP situation and can I license this technology?

The project involved 6 partners across 4 countries (BE, CH, DE, ES), meaning IP is likely shared among consortium members. Licensing terms would need to be negotiated with the coordinator in Spain and the industrial partners. Based on available project data, no open licensing arrangement is mentioned.

How does this handle the ups and downs of renewable energy supply?

This was a core design requirement. The electrolyser was tested under highly dynamic power supplies using a 635 kW wind plant and a 100 kW photovoltaic plant. The advanced communication and control system was specifically built to handle rapid fluctuations typical of renewable energy grids.

What stage of development has this reached?

The project achieved TRL 7 — a prototype validated in an operational environment. They assembled, commissioned, and tested real-scale stacks with the control system. The objective describes this as paving the way for commercial deployment in the next phase.

Does this meet current hydrogen regulations and safety standards?

The system operates at high pressure and was designed for grid integration, meaning it was engineered with safety and regulatory compliance in mind. However, specific certifications or regulatory approvals are not detailed in the available project data. The coordinator in Aragon, Spain specializes in hydrogen technology development.

What kind of technical support is available for implementation?

The consortium includes 2 industry partners, 1 university, and 3 research organizations with deep expertise in hydrogen technology. The coordinator — Fundación Hidrógeno Aragón — is a dedicated hydrogen research foundation. Post-project support would depend on individual partner availability and commercial agreements.

Consortium

Who built it

The ELYntegration consortium brings together 6 partners from 4 countries (Belgium, Switzerland, Germany, Spain), with a balanced mix of 2 industry players, 1 university, and 3 research organizations. The 33% industry ratio and presence of 1 SME signal that the technology was developed with commercial deployment in mind, not purely academic research. The coordinator — a Spanish hydrogen technology foundation — provides sector-specific expertise, while the cross-border team spanning major European hydrogen markets (Germany, Belgium) strengthens the commercial pathway. The EUR 1,861,309 EU investment supported the prototype through TRL 7 validation.

FUNDACION PARA EL DESARROLLO DE LAS NUEVAS TECNOLOGIAS DEL HIDROGENO EN ARAGONCoordinator · ES
VLAAMSE INSTELLING VOOR TECHNOLOGISCH ONDERZOEK N.V.participant · BE
INSTRUMENTACION Y COMPONENTES SAparticipant · ES
RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHENparticipant · DE
IHT INDUSTRIE HAUTE TECHNOLOGIE SAparticipant · CH

How to reach the team

Fundación Hidrógeno Aragón, Spain — a dedicated hydrogen technology R&D foundation

Order a report on this consortium See FUNDACION PARA EL DESARROLLO DE LAS NUEVAS TECNOLOGIAS DEL HIDROGENO EN ARAGON profile →

Next steps

Talk to the team behind this work.

Want an introduction to the ELYntegration team? SciTransfer can connect you with the right technical contact for licensing or collaboration discussions.

Order a report on this topic More in Energy & Climate