HYScale develop high-performance PFAS-free materials for green hydrogen production
A renewable energy project is upscaling innovative high-performance materials to reduce dependency on scarce resources without compromising on performance or efficiency.
Achieving Europe’s ambitious climate goals requires a significant shift from fossil fuels to renewable energy sources.
With the EU aiming to cut greenhouse gas emissions by 40 per cent by 2030 – and up to 95 per cent by 2050 – there is an urgent need for scalable, sustainable energy solutions.
Green hydrogen offers a versatile and clean alternative to decarbonise energy-intensive sectors. However, its widespread adoption depends on overcoming cost, durability, efficiency and resource challenges.
Digital render of the HYScale final Balance of Plant (BoP). Source: HyGear
HYScale – an interdisciplinary EU-funded project focused on upscaling innovative, high-performing CRM and PFAS-free materials and components for Anion Exchange Membrane Electrolysis (AEMEL), is addressing this challenge by upscaling innovative high-performance materials that reduce dependency on scarce resources, without compromising on performance or efficiency.
By replacing CRMs and PFAS, traditionally used in Anion Exchange Membrane-water electrolysers (AEMEL), the project is advancing the first single stack 100 kW AEM electrolyser prototype, making it more cost-effective and environmentally friendly for hydrogen production.
Building on a series of tests, the HYScale team has successfully demonstrated that its 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.
With this progress, HYScale is now one step closer to integrating the stack into a fully functional electrolyser system, targeting a CAPEX of 400 €/kW and advancing towards validation in an industrially relevant environment, reaching Technology Readiness Level 5.
To achieve this goal, optimising individual cell components of a stack is a crucial step. Before scaling up to a full electrolyser system, researchers focused on refining catalysts, membranes, and porous transport layers in small-area cells. This process ensures that each component is fine-tuned for efficiency, durability and long-term operation.
The Italian Centro Nazionale delle Ricerche (CNR) has investigated the influence of the substrate used for the electrode as well as the type of porous transport layer, which was designed and manufactured by Bekaert, employed for the transport of produced gas.
CENmat provided catalyst-coated substrates using high-performance, CRM-free catalysts. CNR and DLR have performed extensive tests to assess both performance and stability of the HYScale components.
A direct comparison with a commercial polymer, Piperion™, has demonstrated the performance advantage of CENmat, PFAS-free AionFLX™ membrane and ionomer. Moreover, durability tests have shown the stability of the HYScale components, meeting the objectives of the project.
Julien Fage, polymer chemist and engineer at CENmat, said: “Scaling up material innovations from lab-scale to industrial electrolysers requires overcoming challenges in durability, manufacturability, and cost-efficiency. HYScale tackles these by integrating advanced materials with scalable processing techniques, ensuring performance and stability at a competitive cost.”
Efforts have focused on optimising the cell structure by reducing frame thickness and validating the materials previously tested in small single cells. With testing now underway as part of the short-stack phase, HYScale is advancing towards integrating these improvements into a fully functional electrolyser system.
A detailed report on HYScale’s latest developments, including technical findings and next steps, is available for download.
For more information, visit www.hyscale.eu.