Australian electrolyser manufacturer Hysata and global green fuels developer InterContinental Energy (ICE) have entered an engineering collaboration to address the single biggest barrier to green hydrogen at scale: cost.
Under the agreement, Hysata will deliver the electrolyser engineering design and performance data for ICE’s Digital Twin Optimisation Framework, supporting ICE’s patented modular P2(H2)Node architecture, designed in Western Australia and now being licensed to developers building some of the world’s largest green fuels projects.
Related article: Hysata to scale electrolyser tech with ARENA grant
Electricity accounts for up to two-thirds of the cost of producing green hydrogen, so efficiency determines whether a project is bankable. Hysata’s capillary-fed electrolyser attacks the problem at the cell level: rather than submerging electrodes in liquid, it draws electrolyte up through a capillary, eliminating the gas bubbles that waste energy in conventional designs. The result is 95% system efficiency, around 20% better than incumbent systems, with a simpler balance of plant that lowers installed cost and complexity.
From the same gigawatt of renewable generation, Hysata’s electrolysers produce around 20% more green ammonia than incumbent systems: roughly 120,000 tonnes more every year, worth on the order of US$100 million annually at current prices.
The P2(H2)Node is ICE’s patented modular architecture that co-locates various electroyser plants with wind and solar generation, eliminating the need for long-distance transmission, lowering costs and improving overall system efficiency. Its standardised design and Digital Twin Optimisation Framework enable developers to optimise integrated project configurations for their specific resources, technology choice and markets. Each one-gigawatt Node is designed to incorporate approximately 800MW of hydrogen production alongside up to 200MW of data centre capacity.
Under the collaboration, Hysata will provide basic engineering design and Digital Twin inputs for an electrolyser system that can form part of the P2(H2)Node architecture.
For Hysata, the agreement is the latest step in a rapid commercial progression: a six-month operational trial with Saudi Arabian energy company ACWA Power in 2025, a first commercial order from a global customer in June 2026, and now an engineering role in one of the most ambitious green fuels architectures in the market.
Hysata CEO Paul Barrett said, “Hysata’s differentiated technology offers the step change electrolysers need to drive down the cost of green hydrogen. High system efficiency dramatically reduces the amount of power a project consumes, which cuts both capex and the levelised cost of hydrogen. These are big projects, and we’re excited to be involved.”
Related article: ARENA backs ICE’s patented Power to Hydrogen Node
InterContinental Energy CEO Alex Tancock said, “Standardisation is how green fuels reach giga-scale. This collaboration enables us to model and optimise Hysata’s ultra-high-efficiency electrolyser technology within the P2(H2)Node framework, giving developers greater cost and performance certainty for large-scale projects.”
