A recent study from Universidade Federal de São Carlos [22.0°S, 47.9°W], in Brazil, has introduced an exciting new approach to hydrogen production using anion exchange membrane (AEM) electrolysis. This research tackles one of the biggest obstacles to making green hydrogen cheaper and more efficient — finding a way to improve the performance of the materials used in electrolysis.
By developing an advanced nickel-iron-sulphide (NiFeS) catalyst, the study shows that it’s possible to make hydrogen production more durable, more efficient, and more cost-effective, without relying on expensive and scarce materials like platinum and iridium.
Why Does This Matter?
Hydrogen is often described as the fuel of the future — a clean energy source that could power industries, transport, and even homes without emitting carbon. But to be truly sustainable, it must be made using renewable electricity rather than fossil fuels.
The problem? Electrolysers—the machines that split water into hydrogen and oxygen — still have technical and economic barriers. The best electrolysers rely on proton exchange membranes (PEM), which require expensive catalysts made from rare metals. AEM electrolysis is emerging as a cheaper alternative, but improving its efficiency has been a major challenge—until now.
A Better Catalyst for Green Hydrogen
The study focuses on the oxygen evolution reaction (OER)—the process that releases oxygen during water splitting. OER is typically sluggish, limiting the efficiency of electrolysers. The researchers designed a self-supported nickel-iron-sulphide (NiFeS) catalyst, which offers major improvements:
- Lower energy requirement – The catalyst requires only 300 millivolts (mV) of overpotential to drive the reaction, significantly less than other non-precious metal alternatives.
- Enhanced durability – It maintained stable performance for over 100 hours, even at high temperatures and current densities.
- Better conductivity – The inclusion of sulphur improves the movement of electrical charges, making the system more efficient.
Unlike traditional catalysts, which often suffer from uneven coating and wasted active sites, the NiFeS catalyst was carefully designed using electrodeposition, a method that ensures even coverage and strong adhesion to the electrode surface.
What This Means for the Future of Hydrogen
This discovery could accelerate the commercialisation of AEM electrolysis, making green hydrogen cheaper and more widely available. Key implications include:
- Cheaper electrolysers – By using abundant materials instead of rare metals, the cost of producing hydrogen could drop significantly.
- Higher efficiency – A more effective catalyst means more hydrogen can be produced using less energy.
- Better long-term performance – Durable materials ensure that electrolysers last longer, reducing replacement costs.
For countries investing in hydrogen, including the UK and Europe, breakthroughs like this bring hydrogen closer to being a mainstream energy source — one that can help decarbonise industries, transport, and homes on a large scale.
Source
Tailoring NiFeS Microstructure through Electrodeposition for High-Performance Anion Exchange Membrane Water Electrolysis, SSRN Preprint, 2025-02-15
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