Optimized CCMs with novel catalyst technology pave the way towards ultra-low iridium electrolysers
15-12-2025
In a collaboration between TNO-VoltaChem and Powall, the ALIVE project (Anode Layer InnoVation for water Electrolysis) aims to significantly reduce the need for iridium in proton exchange membrane (PEM) electrolysers. Using a novel electrocatalytic material, the iridium content of the catalyst coated membranes (CCM) can be lowered to 0.1 mg/cm2 and beyond – a twentyfold reduction compared to current CCMs. This will save cost and reduce dependence on critical raw materials.
The two-year ALIVE project is supported by RVO through the national innovation subsidy scheme EKOO (Energie en Klimaat Onderzoek en Ontwikkeling). It will enable Powall to develop an ultra-low iridium catalyst and validate its performance in a CCM with the support of TNO. The aim is to match the performance and durability of current state-of-the-art CCMs which use high iridium loadings of up to 2 mg/cm2. Given the cost and scarcity of the platinum-group metal, this limits scalability and significantly hampers the potential of PEM electrolysers for large-scale, low-cost hydrogen production.
Breakthrough technology
This project builds on the results of the earlier MIGHTIER project (Materials Innovation for Green Hydrogen To Increase Efficiency and Robustness) which resulted in a patented breakthrough technology for depositing a highly active catalyst. In ALIVE, the focus now is on further optimization of the catalyst and its production, as well as CCM preparation in the anode layer of PEM water electrolysers.
Powall takes the lead in the fabrication of the novel catalyst powders to improve their activity, stability, and conductivity. As Powall CEO Roderik Colen puts it: “We believe in doing more with less. Our encapsulation technology offers unique advantages in protecting and activating ultra-thin coating materials. This breakthrough with TNO could be a key enabler in making electrolysers more cost-effective and unlocking new demand.”
TNO focuses its efforts on improving the performance and durability of the CCM, investigating the relationships between CCM fabrication parameters and their impact on PEM water electrolysers. The goal is to optimize these parameters to enable the production of low-iridium, high-performing CCMs. Finally, the optimized low-iridium CCMs will be benchmarked against the current state-of-the art.
The project aims at bringing the novel catalyst materials close to market introduction, available for CCM manufacturers to produce low-iridium, high performance CCMs. In the meantime, Powall is looking for industrial partners who are interested in early access to their product.
Bring impactful innovation closer to market
According to Martijn de Graaff, Program Director Power-to-X at TNO VoltaChem, “this novel PEM electrolyser product is a great example of how collaboration enables Dutch technology companies to bring impactful innovations closer to market. RVO’s support has been instrumental.” The distinctive expertise developed in the field of CCM fabrication will be of value to the entire supply chain as it will help CCM manufacturers increase the performance of their products, while helping stack manufacturers understand and select better CCMs with lower costs.
Want to know more about the ALIVE project? Contact Jeannet Liang, ALIVE Project Manager, jeannet.liang@tno.nl (TNO) or Sébastien Moitzheim, s.moitzheim@powall.com.
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