As the European Union pursues its target of a 40% reduction in greenhouse gas emissions by 2030 and 95% by 2050, green hydrogen is increasingly viewed as a linchpin of industrial decarbonization.
Yet despite its potential, widespread adoption hinges on overcoming persistent challenges in cost, efficiency, and material sustainability. The EU-funded HYScale project is now demonstrating meaningful progress toward addressing these barriers through innovations in scalable electrolyzer technology.
At the heart of HYScale is the development of an advanced Anion Exchange Membrane (AEM) electrolyzer stack that replaces critical raw materials (CRMs) and PFAS compounds—both high-cost and environmentally problematic—with novel, high-performance alternatives. The project has now successfully scaled a lab-proven material system into a 100 kW prototype, maintaining both performance metrics and material integrity in larger operational settings.
Initial performance tests on the prototype components, carried out by research institutions including CNR and DLR, have confirmed comparable or superior output when benchmarked against commercial alternatives such as Piperion™ membranes. Importantly, HYScale’s AionFLX™ membrane and ionomer—a PFAS-free innovation—achieved these results without compromising chemical durability, a traditional weak point in AEM systems.
Following the success of component-level validation, HYScale has shifted its focus to system-level engineering. A newly developed large-area cell design, led by CNR and supported by partners such as Bekaert and CENmat, now underpins the project’s push toward integrated electrolyser stacks.
This phase is more than a mere scale-up. It integrates innovations such as flow-field-free cell architecture, a design shift aimed at reducing stack thickness, simplifying system integration, and minimizing manufacturing complexity. The absence of a flow field not only lowers production costs but also enables a more compact and lightweight design—attributes that align with industrial deployment requirements.
Cost Targets
One of HYScale’s stated targets is to achieve a capital expenditure (CAPEX) benchmark of €400/kW. Reaching this milestone would position the AEM technology as a competitive alternative to traditional proton exchange membrane (PEM) systems, which remain more costly and dependent on scarce materials like iridium and platinum.
With testing of the short-stack configuration currently underway, the project is progressing toward Technology Readiness Level 5 (TRL 5), marking its transition into validation within industrially relevant environments. The use of validated, scalable materials in conjunction with simplified assembly methods offers a clear pathway for future production at larger scales.
HYScale is funded by the European Union under the Clean Hydrogen Partnership and fits squarely within the EU’s broader hydrogen strategy, which emphasizes domestic manufacturing of key technologies, supply chain resilience, and reduced environmental footprint. The project also aligns with the bloc’s efforts to decouple energy infrastructure from reliance on CRMs and hazardous substances.
With hydrogen demand expected to scale significantly across sectors—from steel and ammonia to heavy-duty transport—projects like HYScale represent not only technical progress but also a testbed for Europe’s strategic autonomy in clean energy technology.
As HYScale enters its next development phase, its results will be closely watched by industry stakeholders and policymakers alike. The outcomes may well shape the future direction of Europe’s electrolyser manufacturing capabilities and its broader decarbonization pathway.
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