USP presents a technological innovation that reduces costs and increases efficiency in the production of green hydrogen. The new membrane-free electrolyzer drives the energy transition and paves the way for more sustainable industrial applications in Brazil.
Em December 9, 2025, USP officially announced the development of a membrane-free electrolyzer Created by researchers from the Polytechnic School and RCGI (Research Centre for Greenhouse Gas Innovation), the innovation was presented as a scientific breakthrough that could reduce costs and increase the viability of gas production. green hydrogen, considered one of the strategic fuels to combat industrial emissions and accelerate the energy transition global.
How did USP develop the membrane-free electrolyzer?
The discovery gained prominence because the membrane is one of the most expensive and fragile components in traditional electrolyzers. Removing it, while maintaining efficient gas separation, could make the entire process cheaper and more robust, expanding access to a fundamental technology for industrial sectors that still depend on fossil fuels.
The equipment created by researchers at Poli-USP breaks with the conventional pattern of electrolyzers used in water electrolysis. In traditional models, the membrane acts as a barrier between the hydrogen and oxygen produced simultaneously. However, this is an expensive component, prone to wear and tear, and responsible for limiting the efficiency of the process.
According to engineer Vitor Bortolin, eliminating the membrane has always been a significant challenge because its absence could allow for the mixing of gases, making safe use impossible. The new prototype circumvents this problem by using a liquid flow to direct the bubbles to opposite sides of the reactor., ensuring the desired separation and reducing operational complexity.
Amaral adds that the solution increases stability and can extend the system’s lifespan. This simplified approach directly contributes to lowering the production costs of hydrogen obtained through electrolysis, especially in industrial plants seeking to reduce maintenance expenses.
Green hydrogen and its role in decarbonization.
O green hydrogen It has gained relevance in the global energy landscape due to its ability to replace fossil fuels in applications that require high energy density. These include steel manufacturing, fertilizer production, heavy transportation, and even aerospace systems.
When electrolysis is powered by renewable sources, such as solar or wind energy, hydrogen becomes a low-impact energy vector. It does not emit carbon dioxide during use and has one of the highest storage potentials among the available alternatives., which makes it strategic for balancing electrical grids.
According to Amaral, storing surplus energy in the form of hydrogen is more viable than resorting to lithium batteries, especially in large-scale scenarios. Batteries require expensive materials and have limited lifespan, while hydrogen can be stored without significant losses over time. This difference helps integrate intermittent renewable energies into industrial and logistical systems.
The development carried out by USP comes at a crucial moment for the energy transition Globally, several countries are increasing investments in hydrogen, including Germany, Japan, Chile, and the United States. In Brazil, the topic has gained prominence in recent initiatives seeking to structure a national production and export chain.
Bortolin emphasizes that the continuous drop in the cost of solar and wind energy opens up opportunities to increase the competitiveness of green hydrogen. However, for this to happen rapidly, it is necessary to reduce the cost of electrolyzers and increase their efficiency—precisely the two points addressed by the innovation created by USP.
With more affordable solutions, the country can combine its abundant renewable energy potential with domestically developed technology., generating economic opportunities and strengthening its strategic position in the global market.
Industrial applications and challenges for reducing emissions.
Hydrogen produced by electrolysis has already been studied as a decarbonization alternative in industrial processes considered difficult to electrify. The steel industry, for example, depends on fossil fuels to reduce ores and reach high temperatures. According to Bortolin, hydrogen represents the most viable alternative to replace coal and natural gas in these operations.
In addition, hydrogen can be used for:
- ammonia and fertilizer production;
- chemical refining operations;
- heavy and long-distance transport;
- Seasonal energy storage in renewable energy systems.
However, producing green hydrogen on a large scale requires more efficient and economical technologies. Research from USP demonstrates that there are ways to reduce these barriers., reinforcing that technological innovation will be fundamental to accelerating the energy transition in different economic sectors.
Other projects under development at RCGI
The Poli-USP team reported that there is other parallel research on electrolysis systems and hydrogen production methods. According to Amaral, the group is working to consolidate metrics that prove the efficiency and stability of the reactors under different operating conditions. This step is essential to validate performance and begin field tests.
The new electrolyzer has already undergone preliminary tests and shown promising results, but it still needs to evolve to reach acceptable levels of continuous operation. Bortolin states that The process of technological maturation is gradual., involving repeated adjustments and tests until the equipment is able to operate safely and with prolonged stability.
The expectation is that, with the advancement of research and institutional support from the university, the equipment will progress to later stages of prototyping and industrial evaluation.
The creation of a membrane-free electrolyzer The research conducted by USP represents a significant step in Brazil’s trajectory of renewable energy development. Technological innovation is fundamental to reducing costs, increasing competitiveness, and enabling countries with high solar and wind potential to expand their participation in the international hydrogen market.
Furthermore, Brazil possesses unique characteristics to thrive in this sector. It has a vast availability of natural resources, renewable expansion capacity, and growing interest from companies and research institutions. Therefore, Advancing scientific research is essential to consolidating a national ecosystem capable of competing globally..
The new technology created by RCGI demonstrates that the country can develop strategic solutions and contribute to a cleaner, more stable, and sustainable energy matrix. As the green hydrogen As innovations gain traction on international agendas, they reinforce Brazil’s role in the low-carbon economy, supporting industry, stimulating investment, and addressing global climate demands.
