Scaling hydrogen production with next-generation electrolysers using thin-film technology
By employing high-tech manufacturing technologies similar to those used in thin-film electronics production, Holst Centre addresses persistent obstacles in scaling sustainable hydrogen production, enabling the development of next-generation, improved electrolysers. Our technology will help reduce the Levelized Cost of Hydrogen (LCOH), encouraging the use of hydrogen to accelerate the energy transition.
The availability of large quantities of affordable green hydrogen will be essential for the energy transition to succeed. In tomorrow’s society we need hydrogen for the storage and transportation of renewable energy, Hydrogen plays a vital role in the transition to renewable energy by addressing seasonal and geographical mismatches between supply and demand. It serves as an effective base to decarbonise fuels in high-energy sectors like aviation and hydrogen can be used directly to power trucks, ships, and vehicles where batteries are impractical. Additionally, hydrogen is used to produce, green ammonia for fertilisers, sustainable synthetic fuels, green steel and it is crucial in the manufacturing of silicon for the electronics industry.
Current challenges hindering hydrogen production
However, scaling hydrogen production is hindered by multiple challenges. Almost all hydrogen currently produced is ‘grey,’ meaning it does not use sustainable electricity and water, and therefore still contributes to global warming. Additionally, current electrolysers are extremely expensive and inefficient, while global installed capacity needs to increase by a factor of 25,000 by 2050 to meet projected demand. This objective is further complicated by the limited availability of critical raw materials, particularly iridium.
Thin-filming manufacturing techniques At Holst Centre, we are dedicated to overcoming these obstacles by applying advanced manufacturing technologies inspired by thin-film electronics, which allow for economies of scale and innovative product designs. Leveraging our experience in thin-film manufacturing for flexible OLED displays, 3D batteries, and photovoltaic cells, we are using our patented processes to create next-generation electrolysers, helping to speed up the energy transition.
Precise material application on 3D microstructures
Our primary strength lies in applying ultra-thin, precise material layers on 3D microstructures at high deposition rates, exemplified by our advanced spatial Atomic Layer Deposition (sALD) processes.
Key advantages include:
Enhanced electrochemical performance: By placing ultra-thin, controlled layers on micro- and nanostructures and integrating 3D microstructured support layers, we create complex components that significantly boost electrolyser efficiency.
Resource efficiency: This technology allows precise material placement, reducing the need for costly raw materials. For example, applying iridium oxide as 5–20 nm layers creates efficient catalysts. On 3D microstructures with seven times larger surfaces, this approach enables electrolysers to use 200 times less iridium than conventional methods.
Precise control and longevity: High deposition rates ensure exceptional control over material thickness and uniformity. This control, along with optimised protective layers, addresses durability issues in electrolysers, extending component life.
Optimally suited for renewable energy: Our focus is on Proton Exchange Membrane (PEM) water electrolysers, ideal for renewable electricity. Nevertheless, our thin-film architecture also suits Solid Oxide Electrolysis (SOE), Anion Exchange Membrane (AEM), and Alkaline Water Electrolysis (AWE), where interface functionality is critical.
Join our shared research programme
With our expertise and technology, Holst Centre aims to establish a strong position for the Netherlands in the global production of green hydrogen. Our goal is to bring together stakeholders across the value chain and invite them to participate in our shared research programme for high-tech manufacturing. Our partners can benefit from a range of tools, from flexible R&D tools to high-volume, large-area mass production tools for both sheet-to-sheet and roll-to-roll production, enabling a seamless transition from lab to fab. Together, we can tackle the challenges to successfully scale up the production of sustainable hydrogen and accelerate the energy transition.