SuperCell boosts future of PEM electrolysis
22-09-2025
This month saw the conclusion of the Shared Research Programme SuperCell. In a cooperation between TNO VoltaChem and the companies Schaeffler, Johnson Matthey, Bekaert and Bosch, a highly performing PEM electrolysis cell was developed. This ‘SuperCell’ constitutes a big step towards more efficient PEM water electrolysers with minimal use of critical raw materials, while featuring industrial operating conditions such as high pressure and intermittent load.
To Richard Braal, Division Director Energy & Materials Transition Industry at TNO, the SuperCell results will boost the future of PEM electrolysis. “Based on the co-operation within the program, the partners further optimized their components, leading to overall improved performance and reduced costs. In the long term, SuperCell will help set new standards for efficiency and cost-effectiveness of PEM cells, lowering the costs of green hydrogen production.”
Each of SuperCell partners contributed with their specific expertise: the German company Schaeffler developed the coated bipolar plates, Johnson Matthey from the United Kingdom was involved in the membranes and cathode catalyst, and the Belgian company Bekaert produced the porous transport layer and its coating. All these partners, complemented with Bosch Transmission Technology Tilburg (the Netherlands), were involved in developing accelerated test protocols. TNO contributed on the ultra-low iridium anode catalyst, led the integration of all components into one cell, and performed testing at TNO’s Faraday Lab in Petten. It featured pressures up to 30 bar, mimicking real-world, high-pressure hydrogen production that reduces the need for downstream compression and lowers overall cost.
Another key feature was the development of an accelerated lifetime test based on wind data recorded by TNO over 10 years from a windmill site at the North Sea. It simulates years of dynamic operation in a short time, helping identify degradation mechanisms under intermittent loads and frequent start-stops. This is essential for offshore wind integration, where electrolysers must be able to respond quickly and reliably to changing power supply.
Future proof
A crucial aspect of SuperCell is the use of materials and catalysts that are ‘future proof’ and low in cost, incorporated in a cell design that is high in performance and efficiency. It features stainless steel bipolar plates coated with non-platinum group materials, and titanium microporous transport layers with a coating that is low in platinum group materials. The catalyst coated membranes are ultra-thin (50 micron) and, the anode catalyst coated membrane is ultra-low in iridium (0.2 mg/cm2). The cell was demonstrated for over 500 hours at hydrogen output pressure of 20 bar and for up to 30 hours at 30 bar without any signs of failure, establishing a performance of 3 A/cm2 and 1.75 V under steady state and dynamic operating conditions.
The partners involved are quite satisfied with these impressive and appealing results. As Sascha Rueth, program manager R&D hydrogen at Schaeffler emphasizes: "Thanks to close cooperation and the sharing of experience and knowledge, the high pressure requirements - especially in combination with a thin membrane - were effectively managed, resulting in promising results." Thomas Favet, R&D project manager at Bekaert's Hydrogen team adds: "Throughout the program, we gained valuable insights into the complexity of the interfaces between the various components of a PEM electrolyser, their integration, and the degradation mechanisms that take place under an accelerated test."
According to Jason Cleeton, Principal Applications Engineer at Johnson Matthey Hydrogen Technologies, the SuperCell programme led to a better understanding of his company’s catalyst coated membranes, in particular those using ultra-thin membranes: “We could establish how they perform in their interaction with other components within the electrolyser stack, identify where the potential risks of failure lie, and how these can be mitigated." He was quite satisfied with the opportunity to demonstrate the capabilities of JM's ultra-thin (50um) membranes, delivering high performance whilst demonstrating the mechanical durability and H2 crossover mitigation required to operate successfully and survive at high (30bar) pressures.
More than the sum of its parts
The prime SuperCell result could only be achieved through the high level of collaboration between the partners – a key aspect of TNO’s concept of a Shared Research Programme (SRP). It involves sharing insights and engaging in technical discussions, hinging on an open mindset and the willingness to accept input from others. As a result, the SuperCell is much more than just the sum of its parts, literally. After all, the key to an optimal system is not just combining the most advanced individual components. It’s about their implementation and integration, with a sharp eye on the end use operating requirements. The introduction of these state-of-the-art components uncovered integration challenges that only became apparent within the SuperCell configuration. Through close collaboration, the partners successfully resolved these issues, demonstrating the strength of the shared development approach.
As Bekaert’s Thomas Favet puts it: “The experience has not only enriched our technical knowledge but has also reinforced our belief in the importance of collaboration in driving impactful innovation. This collaboration provided a great opportunity to combine complementary expertise between leading industrial partners and a renowned technology institute to accelerate the development of green hydrogen.” Electrolyser Test Specialist Gaia Neri of Johnson Matthey adds: “The project has really highlighted how the synergy between the various components of an electrolyser is key to its overall performance and, critically, durability.”
Now that it has become clear what is relevant to realising a SuperCell, this can be used to guide future development. As an example, preparations are under way to start a new Shared Research Program with a special focus on standardisation and harmonisation, which is open for companies to join. If you are interested, or want more information, please contact Tara van Abkoude.
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