Hipercell

Challenge

Green hydrogen production via electrolysis is recognised as a critical technology for climate change mitigation. Unlike conventional hydrogen production, which relies on fossil fuels and generates substantial
CO₂ emissions, green hydrogen is produced with minimal carbon footprint.

Despite its potential, the adoption of green hydrogen is constrained by high production costs, which represent the most significant barrier to widespread deployment. Producing hydrogen from renewable energy sources remains considerably more expensive than producing grey hydrogen from natural gas.

Solution

The Hipercell project aims to achieve substantial cost reductions in green hydrogen production by developing high-performance electrodes and separators for pressurised alkaline electrolysis, suitable for industrialisation and mass production. The objective is to reduce the cost of green hydrogen to a level comparable to, or lower than, that of hydrogen produced from fossil fuels.

The electrode development will focus on creating high-performance Raney-nickel surfaces with enhanced hydrogen and oxygen evolution reaction properties, optimised for cost-effective mass-production methods. The separator development will concentrate on finalising a new, proprietary separator design and the corresponding industrial roll-to-roll manufacturing processes.

Both technologies will be integrated into a commercial electrolyser, enabling hydrogen production at a cost level unattainable with current state-of-the-art electrolysers.

Effect

The measurable objectives of the project are:

1. Development of an electrode surface technology achieving a cell efficiency of at least 80% at a current density of 450 mA/cm², with manufacturing costs below €40 per m².
2. Development of a separator with gas crossover limited to less than 0.4% at rated power and a pressure of 35 bar, with manufacturing costs below €40 per m² and a sales price under €75 per m².
3. Integration of both technologies into Stiesdal Hydrogen electrolysers to reduce the sales price of hydrogen production systems, including balance of plant but excluding owner’s costs, from €1,000 per kW to €560 per kW.