Project Overview

HyReCo is a trinational research project (Germany–France–Czech Republic) that develops a cost‑effective, robust Anion Exchange Membrane (AEM) electrolyser cell designed for industrial mass production. The project targets up to 30% cost reduction for bipolar (half) plates at lab scale, with a perspective of about 80% in industrial application, and approximately 20% improvement in efficiency and lifetime demonstrated via digital twin simulations.

Context and Motivation

Europe is expected to require around 120 GW of green hydrogen by 2030. To meet this ambition, Europe must significantly increase electrolyser production while rapidly and substantially reducing costs in order to produce competitive hydrogen within Europe.

Current membrane‑based electrolysers, in particular Proton Exchange Membrane (PEM) systems, rely on expensive and rare platinum‑group metals such as platinum and iridium and often on PFAS‑based materials. Upcoming PFAS regulations and raw material risks make alternative technologies necessary. Anion Exchange Membrane (AEM) electrolysis is a promising option: it potentially enables low‑cost water electrolysis without expensive catalysts and without PFAS.

However, today’s AEM electrolysers face several critical challenges:

  • Production processes are mostly designed for small cells and small quantities, resulting in high costs.
  • A substantial need to improve the reliability and lifespan of AEM‑EC systems.
  • Three major limitations of current AEM materials:
    • lower hydroxide conductivity (OH⁻ transport ≈ 50–57% of proton transport for the same membrane thickness as PEM),
    • poor chemical stability in highly alkaline environments,
    • degradation of electrolyte and membrane at elevated temperatures.

Objectives of HyReCo

HyReCo aims to develop a cost‑effective, robust AEM cell concept designed for industrial mass production that can be implemented in stacks and systems and used in a wide range of application scenarios. The project focuses on two main quantitative target corridors compared to commercially available cells and components:

  • Reduction of production costs for bipolar (half) plates (BPP / BPP‑HP)
    • Up to 30% cost reduction demonstrated at laboratory / demonstrator scale.
    • Conceptual pathway towards ≈80% cost reduction under full industrial application.
  • Improved efficiency and lifetime of AEM technology
    • Approx. up to 20% improvement in efficiency and lifetime.
    • Proof via simulations and a functional digital twin of the AEM cell and stack.

Technical Approach

HyReCo combines physical development of AEM cell components with advanced modelling, simulation and AI‑based data analysis. The project focuses on component and material development, digital twin and AI, and validation on a laboratory demonstrator.

Components and Materials

Physical investigations cover different feed materials and manufacturing routes for the main AEM cell components: bipolar (half) plates, porous transport layers and membranes/CCMs.

  • Bipolar (half) plates (BPP / BPP‑HP)
    • Ultra‑thin, corrosion‑free graphite‑based composite materials, hot‑pressed into bipolar half plates (developed with Carbon ID).
    • Stretch‑forming steels with intelligent nickel or alternative coatings.
    • Evaluation of cold‑plating technology as a high‑speed corrosion protection method.
    • Flow field designs optimised for pressure drop, reactant distribution and manufacturability.
  • Porous Transport Layer (PTL)
    • Benchmarking Ni foam versus stainless steel (e.g. SS 316L).
    • Variation of thickness and porosity to reduce raw material usage while maintaining performance.
    • Close cooperation with industrial PTL suppliers such as Haver & Boecker.
  • Membranes and CCMs
    • Analysis of commercial AEMs (e.g. Chemours, EVONIK DURAION®, fumasep FAAM‑20 and FAAM‑PK‑75).
    • Accelerated stress tests (alkaline exposure at 80 °C, climate cycling) to obtain comparable durability data.
    • Development of simulation models for hydroxide transport and degradation behaviour, integrating insights from projects such as “105°scaled”.

Digital Twin and AI

HyReCo will build a functional digital twin of the AEM cell and stack. The digital twin is based on detailed chemical‑physical models and reduced‑order, AI‑based models and will be capable of real‑time operation.

  • Structural, electrochemical, fluid‑dynamic, material and degradation models (0D–3D).
  • Simulation of realistic usage scenarios to derive degradation rates for membrane, PTL, BPP and end plates.
  • Reduced‑order models for real‑time digital twin operation.
  • AI approaches including Invertible Neural Networks (INNs):
    • Forward: prediction of voltage, performance and degradation.
    • Backward: estimation of a virtual internal cell state from sensor data.
  • Using simulation and experimental data to generate training data and to optimise cell design for different materials and geometries.

Life Cycle Assessment and Life Cycle Costing

Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) are integrated as cross‑cutting analyses. With support from Capgemini Engineering, HyReCo:

  • evaluates environmental impacts of key materials and processes across the full life cycle,
  • assesses total cost of ownership of the AEM cell and its components,
  • identifies environmental and economic hotspots,
  • provides recommendations for material selection, design decisions and high‑rate manufacturing routes.

Project Structure and Work Plan

HyReCo is organised into five main stages, implemented through six work packages (WP1–WP6):

  1. Stage 1 – AEM Cell Concept Design (WP1, lead: Albert Schmutzler)

    Assessment of designs, materials and manufacturing processes for AEM cell components; definition of requirements; concept of model demonstrator and reference system.
  2. Stage 2 – Development of Functional Models (WP2, lead: UPHF)

    Structural, electrochemical, fluid‑dynamic, material and degradation models; product concept catalogue and validated models.
  3. Stage 3 – Development of AEM Cell Components (WP3, lead: Fraunhofer IWU)

    Optimisation of PTL, BPP/HP, gaskets and membranes; development of HyReCo single cell and 10‑cell demonstrator stack.
  4. Stage 4 – Development of the Digital Twin (WP4, lead: VSB)

    Data architecture and sensor concepts; data collection; AI‑based surrogate models and implementation of the digital twin including LCA/LCC modules.
  5. Stage 5 – Validation and Optimisation (WP5, lead: UPHF)

    Validation of reference system and HyReCo design; evaluation of degradation and manufacturing improvements; optimisation of architecture, materials and operation strategies.

WP6 (Reporting and Knowledge Community, lead: Fraunhofer IWU) ensures project management, reporting and dissemination.

Open Science and Stakeholder Involvement

HyReCo is based on a modular, open AEM cell platform coupled with a digital twin. Open science and open access are central pillars, particularly to facilitate access for SMEs.

  • The 10‑cell demonstrator serves as a shared research platform for early data and component testing.
  • Partners commit to open access for peer‑reviewed publications wherever possible.
  • Source code, reference implementations, APIs, datasets and documentation will be made available via repositories (e.g. GitHub, Zenodo) unless restricted by IPR.
  • Data management follows FAIR principles (Findable, Accessible, Interoperable, Reusable), coordinated by Fraunhofer IWU.

The project is supported by an industrial advisory board and hydrogen clusters such as HZwo e.V., the Moravian‑Silesian Hydrogen Cluster and French clusters (e.g. Tenerrdis). Regular workshops, project colloquia and public events ensure access to results and feedback from industry, research and policy stakeholders.