SciTransfer
EXSOTHyC · Project

High-Efficiency Green Hydrogen Production Using Low-Energy Alkaline Electrolysis

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Imagine a water-splitting machine that usually wastes a lot of electricity to work fast. This project is like upgrading the engine and the filters to make it run much more efficiently at lower power. By using special nanoparticles, it cuts down the electricity bill needed to produce each kilogram of hydrogen.

By the numbers
48 kWh/kg
Target electricity consumption at nominal capacity
1.0 A/cm2
Target current density
0.3
Maximum use of critical raw materials as catalysts
500 GWh/year
Potential energy savings per GW of capacity
The business problem

What needed solving

Current alkaline electrolysers are too expensive to operate because they prioritize speed (current density) over energy efficiency, leading to power consumption above 54 kWh/kg.

The solution

What was built

A novel electrolyser stack including catalyst coated diaphragms (CCD), Zirfon membranes with reduced HTO, and transition metal phosphide catalysts.

Audience

Who needs this

Alkaline electrolyser manufacturersGreen hydrogen plant developersIndustrial decarbonization consultantsChemical plant operators
Business applications

Who can put this to work

Chemical Manufacturing
enterprise
Target: Industrial ammonia or methanol producer

If you are a chemical producer dealing with high electricity costs for hydrogen feedstocks — this project developed a new stack design that reduces electricity consumption to 48 kWh/kg. This lowers the operational expenditure of your green hydrogen plant.

Energy Infrastructure
enterprise
Target: Green hydrogen plant operator

If you are a plant operator dealing with high energy bills and critical raw material shortages — this project developed catalysts with critical raw material use below 0.3 for alkaline cells. This reduces both your OPEX and supply chain risk.

Heavy Industry
enterprise
Target: Steel mill transitioning to hydrogen

If you are a steel manufacturer dealing with the high cost of decarbonizing heat — this project developed a catalyst coated diaphragm (CCD) that improves voltage efficiency. This helps lower the levelised cost of hydrogen for large-scale industrial use.

Frequently asked

Quick answers

How does this reduce the cost of hydrogen production?

It prioritizes efficiency over current density to lower operational expenditure. The target is to reduce electricity consumption to 48 kWh/kg, which directly lowers the levelised cost of hydrogen.

At what industrial scale is this being tested?

The project uses a combination of single cell, SRU, and short stack level validation. Based on available project data, it aims for a current density of 1.0 A/cm2.

What is the IP or licensing status of the technology?

Based on available project data, specific licensing terms are not provided, but the project develops disruptive components like Zirfon membranes and catalyst coated diaphragms.

When will the CAPEX and O&M costs be available?

CAPEX values in terms of €/(kg/d) and €/kW are scheduled to be provided by month 24 (M24) of the project.

How does this integrate with existing alkaline systems?

The project develops a novel stack design and membrane electrode assemblies based on Zirfon that can replace current high-voltage components to improve efficiency.

Consortium

Who built it

The consortium consists of 5 partners across 5 countries (BE, DE, EE, NL, UK) with a 40% industry ratio (2 industrial partners). This balance suggests a strong transition from academic research (2 universities, 1 research center) toward industrial application, led by an SME coordinator specializing in hydrogen solutions.

How to reach the team

Contact OU Stargate Hydrogen Solutions in Estonia

Next steps

Talk to the team behind this work.

Contact us to explore licensing opportunities for high-efficiency alkaline electrolyser components.