Scientists affiliated with the Center for Innovation in New Energies (CINE) have developed a faster and more economical method to manufacture the central component of the electrolyzer, the machine responsible for extracting hydrogen by breaking water molecules. According to an article published in Science Direct on June 10, 2026, the national innovation focuses on the development of the anode, the piece that separates and releases oxygen during the chemical process.
The technique uses a thin film of metal oxides (composed of ruthenium and manganese) on a titanium base. By applying innovative thermal treatments with microwaves and lasers, the research managed to reduce operational costs, electricity consumption in manufacturing, and increase the equipment’s lifespan. This discovery represents a decisive step for the industry to adopt green hydrogen on a large scale, removing economic barriers that previously limited the advancement of clean energy.
The challenge of oxygen separation in the electrolyzer of green hydrogen
To understand the relevance of this breakthrough, it is necessary to look at the heart of the electrolyzer. The equipment works by separating the oxygen and hydrogen that make up the water molecule. For hydrogen to form at the opposite end of the device (the cathode), a massive amount of energy is required at the anode to release the oxygen. It is precisely to contain this severe expenditure that industry and academia turn to catalysts, chemical elements applied to the surface that facilitate the reaction.
In practice, the better the efficiency of this coating, the lower the factory’s electricity bill will be, generating a competitive input for the global energy transition. The industry’s great obstacle has always been finding materials that balance high conduction, low cost, and resistance to severe degradation caused by the chemical reaction.
The team tested different proportions of oxides applied directly to the titanium anode to find the ideal composition. To discover the best “recipe” for the coating, the scientists evaluated three thermal treatment methodologies:
- Conventional laboratory oven, which serves as the traditional base for comparison;
- Microwave radiation, focused on rapid and uniform heating;
- Laser treatment, which acts in a concentrated and highly precise manner.
The systematic variation of these techniques allowed mapping how each type of heat alters the molecular organization of the thin film. The practical result was the discovery of structures much more stable and efficient than those obtained by traditional metallurgical methods.
Thermal innovation and real gains in green hydrogen
Laboratory tests demonstrated that microwaves and lasers drastically reduce the time required for manufacturing the parts. In the context of a production line, less processing time results in direct savings in the factory’s electricity consumption. Researcher and professor Elton Sitta, from the Federal University of São Carlos (UFSCar), explains that the heating method dictates the physical properties and final electrocatalytic performance of these materials.
From a practical standpoint, these two techniques generate much more active structures to operate at the heart of the electrolyzer. According to the professor’s analysis, the microwave system stands out for its ease of integration into large-scale manufacturing and mass production. On the other hand, the use of lasers meets the precise needs of automated and continuous flow electrode manufacturing industries.
This versatility ensures that industries with different profiles can adopt the technology to produce cheaper components. As a consequence, the assembly cost of green hydrogen plants decreases, accelerating the replacement of fossil fuels with clean energy matrices.
From the PEM membrane to direct tests in seawater
The stability of this new titanium anode was put to the test in real and extremely demanding scenarios. The first involved conditions similar to those found in proton exchange membrane systems (known by the acronym PEM). This is currently one of the most promising technological routes on the market to generate low-carbon hydrogen with high yield and operational flexibility.
Next, the group took an even bolder step and used saltwater directly in operational tests. Using ocean water is a masterstroke to mitigate the ecological impacts of the activity, protecting Earth’s freshwater reserves. Furthermore, it allows production plants to be installed in strategic coastal regions, facilitating export logistics to other countries.
On this aspect, Elton Sitta celebrates the high catalytic capacity and resilience demonstrated by the thin films generated by laser and microwaves. Even operating in the highly corrosive environment of seawater and in an acidic medium, the parts maintained their structural integrity and functionality. This solves the chronic problem of premature oxidation that often renders traditional electrodes useless when exposed to sea salt.
The power of cooperation and the patents that finance the future
This significant scientific advancement is the result of an interregional and multidisciplinary collaboration that brought together different centers of excellence:
- UFSCar: Leading hub in operational investigations, electrochemical tests, and oxide treatment.
- Universidade Tiradentes (Unit): Institution based in Sergipe that actively participated in the preparation, synthesis, and detailed analysis of the material’s physical properties.
Postdoctoral researcher Isabelle M.D. Gonzaga, the first author of the scientific publication, emphasizes that this union reinforces Brazil’s technological sovereignty and scientific research in the green hydrogen sector. The study took place under the umbrella of the CINE Low Carbon Hydrogen program, an Applied Research Center created in 2018 through a strategic partnership between FAPESP and Shell. The center has shared headquarters at Unicamp, USP, and UFSCar, with active collaboration from 8 other Brazilian institutions.
The financial support and laboratory infrastructure were provided with direct resources from FAPESP through specific funding projects, cataloged under the following institutional control numbers:
- FAPESP Project 24/16986-7;
- FAPESP Project 21/12394-0.
The maintenance of this shared funding ecosystem between the private and public sectors demonstrates how long-term investment in science translates into valuable market solutions. The direct result is the generation of national intellectual property capable of attracting the attention of international players in the energy market.
The future of electrolyzers in the global decarbonization scenario
The success of tests with the titanium anode coated with a thin film of oxides opens a realistic horizon for the rapid decarbonization of heavy industries. By reducing the manufacturing cost of the electrolyzer, Brazilian science removes one of the main economic barriers that prevented the large-scale adoption of this fuel. Hard-to-electrify sectors, such as steelmaking, fertilizer production, and long-distance maritime transport, gain a financially viable alternative.
By enabling the direct use of seawater and significantly reducing the electricity consumed in the electrolysis process, the national project preserves ecosystems and positions the country as a key exporter of ecological solutions. It is a concrete response to the challenges of the energy transition, proving that the union between academia and corporate investment generates efficient, affordable technologies ready to transform the fuel matrix in the global market.
