New PEM Electrodes Validated in the Laboratory
The materials component of the project centres on the development and validation of electrodes for PEM electrolysis. The ITE team formulated catalytic inks and developed a spray-deposition manufacturing process. This approach yields materials with adequate homogeneity and reproducible behaviour, two characteristics considered essential for future industrial scale-up. The produced electrodes were then subjected to thorough physicochemical and electrochemical characterisation under representative operating conditions, with performance benchmarked against reference solutions available on the market.
In parallel, Hedera identified and analysed the main degradation mechanisms affecting PEM electrodes under different operational conditions, with a particular focus on scenarios involving the integration of photovoltaic and wind energy surpluses. This work highlighted the impact of current variations and load profiles on component ageing. “A large part of the viability of renewable hydrogen for applications such as heavy mobility or certain industrial uses hinges on the electrolyzer,” said Alejandro Rubio, the project’s lead researcher at ITE, noting that the challenge lies in “producing hydrogen flexibly using sun and wind without penalising equipment lifespan or driving up operating costs”.
Digital Tools to Optimise Electrolysis Plant Management
Drawing on the experimental data gathered, ITE developed and validated a predictive degradation model for PEM electrodes. The tool aims to estimate system behaviour under representative conditions and to anticipate the impact of different operational strategies on electrolyzer lifespan and on the cost per kilogram of hydrogen produced. Hedera also delivered a multi-criteria optimisation algorithm for hydrogen production systems, incorporating variables such as renewable energy availability, demand, storage and equipment degradation. The tool is designed to support decision-making in the design and management of electrolysis plants.
The project additionally delivered a digital twin of an electrolysis plant, oriented towards scenario simulation and the validation of energy management strategies. This tool enables virtual assessment of different operating configurations and renewable coupling strategies before they are transposed to a real facility. The push for PEM electrolysis competitiveness is unfolding in an international context where large-scale industrial projects are multiplying: ANDRITZ and RAG Austria have launched Austria’s largest green hydrogen installation, reflecting mounting pressure on production costs. Within Spain itself, hydrogen is being pursued through other approaches as well: Mantle8 has secured two natural hydrogen exploration permits covering 960 km² on Spanish territory. The results of the Hedera project aim, according to ITE, to “translate electrochemical and operational complexity into practical rules and tools for better designing and managing future electrolysis plants”.
