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

Project Information

HYScale

Grant agreement ID: 101112055

DOI

10.3030/101112055

EC signature date 26 May 2023

Start date 1 June 2023

End date 31 May 2027

Funded under

• Climate, Energy and Mobility

Total cost

€ 5 295 799,25

EU contribution

€ 5 295 799,25

Coordinated by

CUTTING-EDGE NANOMATERIALS CENMAT UG HAFTUNGSBESCHRANKT
Germany

Periodic Reporting for period 1 - 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)

Reporting period: 2023-06-01 to 2024-11-30

Summary of the context and overall objectives of the project

The HYScale project is a pioneering EU-funded initiative aimed at advancing green hydrogen production through the development of a novel, highly efficient, and cost-effective alkaline membrane water electrolysis technology. This technology is distinct because it operates without the need for critical raw materials, thereby addressing some of the key sustainability and cost issues associated with current hydrogen production methods. By focusing on optimizing materials synthesis and components production, HYScale seeks to upscale electrolyzer technology to achieve a significant reduction in capital expenditure (CAPEX) while maintaining high efficiency and durability. A major goal is to integrate this technology into a functional electrolyzer system, validate its performance in an industrially relevant environment at a Technology Readiness Level (TRL) of 5, and demonstrate its potential to significantly lower the cost of green hydrogen production. This initiative not only supports the EU's ambitious targets for reducing greenhouse gas emissions by facilitating the transition to a renewable energy economy but also positions Europe at the forefront of green hydrogen technology innovation and deployment.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The HYScale project has made substantial progress in the development and optimization of anion-exchange membrane (AEM) water electrolysis technology, focusing on scalability, efficiency, and cost reduction. Below is a structured overview of the technical and scientific achievements:

1. Membrane and Ionomer Development

Upscaling of AionFLX Membrane: Production has been scaled to accommodate 400 cm² large-area single cells, ensuring high reproducibility and efficiency.
Hydrogen Crossover Reduction: Implemented membrane reinforcement strategies, improving safety and longevity​

2. Stack Prototyping and System Integration

Developed a large-area single cell (~400 cm²) as the base unit for stack assembly.
Achieved faradaic efficiencies exceeding 98% in long-term tests (~110 hours).
Conducted stack testing under dynamic grid conditions to assess performance in renewable energy integration scenarios​

3. Materials and Component Optimization

Catalyst Optimization: Developed critical raw material (CRM)-free catalysts with dual-layer porous transport layers (PTL) to improve gas transport and adhesion.
PTL Material Innovation: Developed stainless steel PTLs to lower nickel content while maintaining performance​

4. Stack Development and Testing

Validated operational feasibility at 2 A/cm² with a cell voltage of 2.07V in 0.1M KOH.
Designed and tested short-stack prototypes (3–5 cells, 400 cm² active area), targeting TRL5 validation.
Durability tests on small-area cells (4 cm²) at DLR showed stability up to 330 hours with a degradation rate of less than 5 µV/h​

5. Industrial Demonstration Preparation

HyGear's role: Provided system integration input to support the transition from stack prototypes to full electrolyzer demonstrators.
100kW Stack Design: Preliminary designs focus on cost-effective balance-of-plant (BoP) and industrial scalability​

6. Economic and Environmental Performance Assessment

Targeting CAPEX of €400/kW, a significant reduction compared to current benchmarks.
Techno-economic and lifecycle assessment (LCA) initiated, with early analyses showing lower environmental impact compared to conventional electrolysis technologies​

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The HYScale project advances cost-effective, high-efficiency, CRM-free alkaline membrane electrolysis for large-scale green hydrogen production. Below is a summary of key results, impact, and commercialization requirements.

1. Key Results
1.1. Technological Advancements

Materials Development:

AionFLX™ membranes upscaled to 400 cm², maintaining high performance with minimal degradation.
Optimized CRM-free catalysts (OXYGN-N, H2GEN-M) reduce CAPEX.
Gradient-porosity PTLs enhance gas transport and lower nickel dependency.
Stack & System Progress:

400 cm² single cell achieved 2 A/cm² at 2.07 V in 0.1 M KOH, exceeding small-cell performance.
Short-stack (3–5 cells, 5–6 kW) finalized with cost-effective components.
100 kW electrolyzer system in design for scalability.
Durability & Performance:

98% faradaic efficiency demonstrated; long-term testing ongoing.
High current density achieved with reduced hydrogen crossover, enhancing safety and efficiency.
1.2. Economic & Market Impact

Cost Reduction & Competitiveness:

CAPEX projected at 400 €/kW, outperforming PEM (>1,000 €/kW).
OPEX reduced via high-efficiency membranes, optimized stack design, and BoP improvements.
LCOH targeted below 3 €/kg H2, making green hydrogen competitive.
Scalability & Value Chain:

Covers full hydrogen value chain from materials to system demonstration.
Supports gigawatt-scale deployment aligned with EU clean hydrogen goals.
Industrial & Research Collaboration:

Consortium of industry leaders, SMEs, and research institutes driving commercialization.

HYScale concept infographic

Map of partners

HYScale logo

WP organisation