Renewable hydrogen is at the heart of the global shift toward cleaner energy. By transforming green electricity into hydrogen molecules, we can store power more effectively, transport energy easily, and reduce greenhouse gas emissions. At TNO, our mission is to drive this innovation forward by working alongside industry partners to develop and validate next-generation electrolyser technologies.
A major focus of our work within the CLEANHYPRO project is solving a critical supply chain hurdle: the use of rare materials in Proton Exchange Membrane (PEM) electrolysers.
The Iridium Challenge
The world produces only about 7.7 tonnes of iridium each year. However, as the demand for green hydrogen scales up, we expect to need enough electrolyser capacity to consume roughly 85% of that yearly production by 2030.
For green hydrogen to reach its full potential, we must find ways to use significantly less iridium without losing performance or durability. Current technologies often struggle to reduce these rare materials because thin layers can sometimes lead to poor electrical conductivity or uneven structures.
Innovations in Thin-Film Coating
TNO is tackling this problem using a highly precise technique called spatial Atomic Layer Deposition (s-ALD). This method allows us to create incredibly thin, uniform catalyst layers on both membranes and transport layers.
Our research has led to several breakthroughs:
Massive Material Savings: We have successfully demonstrated catalyst layers that use 10 to 20 times less iridium and platinum compared to standard versions used today.
High Performance: Despite using far less material, these components still reach the high-performance levels required for industrial use.
Anti-Corrosion Expertise: We apply ultra-low amounts of platinum as protective layers to ensure the equipment lasts longer and stays efficient.
Partnering for an Industrial Future
Through the CLEANHYPRO Open Innovation Test Bed (OITB), TNO is actively helping the industry develop and validate these low-loading catalyst layers. By combining our manufacturing expertise with a full suite of testing tools, we are helping technology suppliers and high-tech equipment companies secure their place in the international hydrogen supply chain.
These advancements prove that we can build more with less, moving us one step closer to a sustainable and cost-effective hydrogen economy.
Author(s):
R.C. Makkus
J. Shen
D. Ripepi
C. Sidney Santana
Partner organisation:
TNO-Holst Centre
