IDTechEx projects the annual market for water electrolyser components to surpass US$10 billion ($15.40 billion) by 2036.
This growth is poised to be driven by an anticipated surge in demand for electrolyser systems as green hydrogen projects gain momentum and achieve commercial maturity.
To better compete with PEM electrolysers on efficiency, some manufacturers enhance these electrodes with platinum group metals (PGMs) and rare earth oxides.
For example, platinum can be added to the cathode formulation, while mixed metal oxides containing ruthenium or iridium can be used for anodes, as showcased by products from De Nora.
Beyond catalyst composition, IDTechEx notes innovation is also occurring in electrode substrates and manufacturing. Nickel foams and felts are being explored as alternatives to conventional porous plates and meshes.
“A major trend is the adoption of advanced electrode coating processes,” reports IDTechEx.
“Jolt Solutions, for instance, has developed the Sparkfuze process, which uses exothermic reactions to form the catalyst from precursors in just one or two cycles.
“This method is faster, more energy-efficient, and less costly than the conventional ‘coat-and-bake’ technique, which requires multiple coating and high-temperature drying steps.
Diaphragms are also a key area of innovation. While Zirfon (a zirconia-polysulfone composite) remains the industry standard, new production methods are emerging. Novamem, for instance, has developed a process where nanoparticles are embedded within a polymer and then dissolved, leaving behind a highly optimised porous network for electrolyte flow.”
Long history
The electrolyser sector has a history of benefiting from continuous innovation, and this trend is set to continue, says IDTechEx. Even in relatively mature component areas, the research firm says there is still substantial room for improvement.
The solid oxide electrolyser (SOEC) is an emerging technology defined by its high operating temperatures (600-900°C). This high-temperature operation boosts electrical efficiency and allows for the use of industrial waste heat in the process.
IDTechEx reports SOEC technology has benefited significantly from parallel developments in solid oxide fuel cells (SOFCs).
Conventional SOEC designs are “electrode-supported” or “electrolyte-supported”, where one layer provides structural integrity.
A key trend is the shift towards “metal-supported” cells, where the active layers are coated onto a porous stainless-steel support. This design, commercialized by Ceres Power, allows for thinner cell layers while gaining the structural durability of stainless steel.
“Another significant trend is the push towards lower operating temperatures to reduce energy requirements,” IDTechEx says.
“This has led to the adoption of alternative electrolytes like gadolinia-doped ceria (GDC), which can operate at 600°C compared to the 800°C needed for traditional yttria-stabilised zirconia (YSZ).
“This shift requires adapting the electrode materials to the new electrolyte. Topsoe is a key developer that has successfully commercialised SOEC systems based on this lower-temperature GDC technology.”
The global transition towards hydrogen use in industrial, transport, and energy sectors is accelerating, driven by a concerted effort from governments and industries to decarbonize sectors where direct electrification is challenging.
Green hydrogen, produced via renewable-powered water electrolysis, has become a leading solution, with significant investments aimed at establishing gigawatt-scale production capacities by 2030.
According to IDTechEx, the pivot to green hydrogen not only offers a viable path to reduce emissions in heavy industry and transportation but also enhances energy security and creates new market opportunities in energy storage and sector coupling.
“At the heart of the green hydrogen revolution lies the evolution of materials and components within electrolyser technologies. Advancements in this area are pivotal, aiming to boost electrolyser efficiency, extend longevity, and mitigate reliance on scarce materials,” the research firm adds.
“For example, innovations in PEMEL technology, such as catalysts with reduced iridium content, could significantly alleviate supply chain vulnerabilities associated with iridium’s limited availability.”
IDTechEx provides a comprehensive analysis of the key materials and components across the four electrolyser technologies, emphasising both established solutions and prospective advancements. Components analysed include membranes, catalysts, electrodes, porous transport layers (PTL), gas diffusion layers (GDL), bipolar plates, coatings, gaskets, and end plates, offering insights into their current and future states.
Manufacturing methods and potential innovations are also discussed.
Write to Adam Orlando at Mining.com.au
Images: IDTechEx
