Author Archive: Hyprael

ZIRFON membranes logo for alkaline electrolysis - HYPRAEL project innovation.

ZIRFON™ membranes for alkaline electrolysis at commercial scale: supporting the hydrogen economy through HYPRAEL

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Agfa-Gevaert’s role in the hydrogen economy

Green hydrogen is becoming a key driver for decarbonizing industry, particularly in sectors that are difficult to electrify such as ammonia, steel, and petrochemicals. Of the available production technologies, alkaline electrolysis is widely recognized for its scalability and favorable cost structure. Within this landscape, Agfa-Gevaert supports the transition to green hydrogen by supplying Zirfon membranes, which are an essential component of alkaline water electrolyzers.

ZIRFON prototype diaphragm developed within the HYPRAEL project for high-pressure alkaline electrolysis.

Figure 1: The ZIRFON™ prototype diaphragm, developed within HYPRAEL.

Membranes in alkaline electrolysis, how does it work?

The membrane is a core element of an alkaline electrolyzer. It physically separates the cathode and anode, preventing hydrogen and oxygen from mixing and thereby avoiding the formation of explosive gas combinations. At the same time, the membrane must enable efficient ion transport, which is crucial for maintaining high performance and overall system efficiency.

Why Zirfon? Safe, scalable and proven

Zirfon membranes are designed for safe and dependable operation, including in systems powered by variable renewable energy sources. More than 4 GW of Zirfon membranes have been supplied worldwide, with no safety incidents reported over more than 15 years of industrial operation. This proven track record demonstrates the maturity of the technology. By integrating Zirfon membranes, customers can reduce the cost per kilogram of green hydrogen by more than 50 percent, improving the economic feasibility of projects in a market that still faces high costs and supply chain challenges. In September 2025, Agfa-Gevaert will open the world’s largest alkaline membrane production facility, supported by an €11 million EU Innovation Fund grant. The facility will have an annual capacity of 1 million m² of Zirfon membranes to meet increasing global demand.

Electrochemical testing on new prototype diaphragm conducted by Fraunhofer IFAM for HYPRAEL.

Figure 2: Electrochemical testing by Fraunhofer on new prototype diaphragm.

Innovation within HYPRAEL

In HYPRAEL, we are developing separators for operation at elevated temperatures and pressures, specifically 120°C instead of 90°C, and up to 50 bar as a means of pushing electrolyzer efficiency further than previously possible. Together with Syensqo, Agfa has developed a new diaphragm that can withstand these demanding conditions. Electrochemical performances of this new diaphragm were confirmed thanks to an AEL single cell prototype developed by our partner Fraunhofer IFAM, Dresden. Research carried out by Syensqo provided access to a next-generation polymer enabling the development of a diaphragm with unprecedented performance in harsh environments inside alkaline water electrolyzers. This work positions HYPRAEL at the forefront of innovation for next-generation high-performance alkaline electrolysis systems.

Collaborating for Excellence Learn more about the world-class partners making HYPRAEL possible. Explore our Partners & Consortium →

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Vanesa Gil researcher at FHa testing pressurized electrolysis materials for HYPRAEL project

Breaking the Hydrogen Barrier: Vanesa Gil’s Scientific Leadership in HYPRAEL

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Vanesa Gil, ARAID leading researcher at the Aragon Hydrogen Foundation (FHa), is driving the HYPRAEL project (Horizon Europe) to achieve near-zero energy loss in pressurized green hydrogen production using advanced alkaline electrolysis and 50 kW industrial scaling.

Green hydrogen is not just a chemical formula; it is the result of years of experimentation, rigor, and vision in the laboratory. Within the HYPRAEL project, funded by the Clean Hydrogen Partnership, this journey has a key name in European energy research: Vanesa Gil.

Based at the Walqa Technology Park in Huesca (Aragon), Vanesa Gil leads one of the most ambitious challenges of Horizon Europe (Grant Agreement 101101452): producing pressurized hydrogen at 80 bar without expensive mechanical compression. Her work bridges materials science with the reality of a decarbonized industrial sector in the European Union.

Real Science for a Real World: From 10 cm² to 50 kW

Science is often perceived as abstract, but Vanesa’s work is purely tangible. She architects the validation of innovative 3D structured electrodes and APS coatings—developed with partners like Fraunhofer (Germany) and VECO (Netherlands)—performing under extreme conditions up to 120Cº.

“What motivates me about HYPRAEL is seeing how an innovation born in a 10 cm² cell successfully scales to a 50 kW industrial stack,” says Gil. This scale-up is crucial for the European Green Deal and the energy resilience of the Aragon Hydrogen Valley.

Role Models Inspiring the Green Economy

The “Women Breaking the Hydrogen Barrier” campaign highlights Vanesa Gil as a reference in STEM. In a sector where the gender gap remains a challenge, her leadership aligns with Sustainable Development Goals (SDGs) 5, 12, and 13.

An In-depth Conversation with Vanesa Gil

Q: What motivates you the most about working on a project like HYPRAEL, which aims to eliminate energy losses in hydrogen production?

Vanesa Gil: “As an ARAID researcher, my R&D is driven by intellectual curiosity, the pursuit of solutions to complex problems, and continuous learning. Above all, I am moved by the desire to generate a positive impact on society from a place as humble yet significant as the FHa.”

Q: What has been the most exciting technical challenge in scaling materials from a 10 cm² cell to a 50 kW industrial stack?

Vanesa Gil: “The greatest challenge in research is climbing that endless staircase from concept to industrial transfer. Rigor and reproducibility are essential. As we scale up, the challenges become more complex, making it vital to have multidisciplinary teams with complementary skills to solve the diverse hurdles that arise.”

Q: What would you say to a girl who dreams of being a scientist but feels that engineering or energy are distant worlds?

Vanesa Gil: “You cannot dream of what you do not know exists. Fortunately, there are more and more role models today that allow you to dream of these supposedly distant worlds. In science, curiosity is the spark that drives exploration, but discipline is the fuel that keeps the engine running. We must never stop being children—like an eternal Peter Pan—keeping that curiosity alive while applying the discipline needed to turn dreams into real achievements.”

Q: In one sentence, how do you believe your work in the laboratory today will change people’s lives in the next 10 years?

Vanesa Gil: “Our work is fundamental to social development as it translates scientific discoveries into practical solutions, directly contributing to climate change mitigation and resource efficiency.”

 

 

Climate Impulse aircraft powered by Syensqo green hydrogen technology

Green Hydrogen: The 9-Day Flight Making Aviation History

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The Climate Impulse project has confirmed a critical technological milestone: the validation of Syensqo’s Aquivion® ion-exchange polymers. This material serves as the “chemical heart” of the fuel cell that will power the first non-stop, zero-emission round-the-world flight.

As a strategic partner, HYPRAEL celebrates this expansion of Syensqo‘s hydrogen portfolio. This breakthrough demonstrates that zero-emission long-range aviation is no longer a distant vision, but a tangible reality ready for testing in Châteauroux.

“Climate Impulse exemplifies how science, innovation and partnership can come together to address some of the most complex challenges of our time,” says Mike Radossich, CEO of Syensqo. “With our lightweight composite materials and now confirming our ion-exchange polymer material at the heart of the chemical reaction, we are demonstrating how advanced materials can help turn the ambition of zero-emission non-stop round the world flight into a tangible reality.”

The aircraft’s structure, built with cutting-edge composite materials in Les Sables d’Olonnes, is now preparing for initial test flights in Châteauroux. This project not only showcases Syensqo’s technical leadership but also reinforces HYPRAEL’s mission to drive hydrogen solutions that spearhead global decarbonization.

Group of hydrogen researchers and partners at the 5th FRH2 CNRS Plenary Meetings in France.

Syensqo presents HYPRAEL Project at CNRS Hydrogen Plenary in Annecy, France

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Bertrand Pavageau (Syensqo) showcased HYPRAEL’s advancements in alkaline electrolysis at the 5th FRH2 CNRS Plenary Meetings in Annecy. This event, gathering 260 experts from French and European hydrogen laboratories, underscores HYPRAEL’s role in the EU’s Green Hydrogen roadmap.

Strategic Collaboration in the Auvergne-Rhône-Alpes Region The HYPRAEL consortium continues to bridge the gap between industrial application and academic excellence. During the 5th Plenary Meetings of the CNRS Hydrogen Research Federation (FRH2) in Annecy, Bertrand Pavageau, Hydrogen Expert at Syensqo, delivered a pivotal talk on the synergy between Syensqo’s H2 roadmap and key European collaborative projects like HYPRAEL.

Driving Innovation in Alkaline Electrolysis As a flagship initiative funded by the Clean Hydrogen Partnership, HYPRAEL focuses on high-performance electrolysis. Pavageau’s presentation highlighted how industrial-academic cooperation is essential for:

  • Scaling Up: Transforming lab-scale breakthroughs into industrial-grade electrolyzers.

  • Decarbonization: Supporting Europe’s Net Zero targets through advanced materials.

  • Networking: Strengthening ties with the 30 laboratories of the FRH2 and the CEA.

Annecy: A Hub for Hydrogen Research With record-breaking attendance (260 participants and 160+ presentations), the event in the Auvergne-Rhône-Alpes region confirmed France’s position as a vital node in the European hydrogen ecosystem. The conference, organized by IRCELYON, provided a unique platform for HYPRAEL to engage with PhD students and senior researchers, ensuring the project’s technical insights reach the next generation of scientists.

Bertrand Pavageau from Syensqo presenting the HYPRAEL project at CNRS FRH2 in Annecy.

Bertrand Pavageau (Syensqo) showcasing HYPRAEL’s roadmap.

Vanesa Gil FHA presenting HYPRAEL high-pressure H2 production at X-SEED Workshop Milan.

Leading the High-Pressure Dialogue: HYPRAEL at the 2nd X-SEED Workshop

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The industrial hydrogen landscape gathered yesterday at Snam’s facilities in Milan for a pivotal event: the 2nd X-SEED Workshop. The focus was clear—linking high-pressure production with the real-world needs of end-users.

As the coordinating entity of the HYPRAEL project, we played a central role in the technical agenda. Vanesa Gil (FHa) presented our latest findings on materials development for pressurized electrolysis. Her presentation detailed how our innovative cell designs and advanced electrocatalysts are achieving high-pressure H2 production with the potential for near-zero energy loss.

By participating in this technical forum, HYPRAEL continues to strengthen the circular economy and ensure European leadership in hydrogen technology.

3D structured electrode for alkaline electrolysis developed by Veco

3D Electrodes for Green Hydrogen: Veco Revolutionizes Alkaline Electrolysis

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New electroforming technology reduces costs and increases efficiency in green hydrogen production | Renewable energy innovation

Veco together with Fraunhofer have developed 3D structured electrodes that promise to transform the green hydrogen industry through high-efficiency water electrolysis, a key technology for energy decarbonization in Spain and Europe.

High-efficiency electrodes: The key to competitive green hydrogen

Veco’s new electrodes for alkaline electrolyzers incorporate 3D electroforming technology that significantly improves the performance of HER (hydrogen evolution reaction) and OER (oxygen evolution reaction), fundamental processes in renewable hydrogen production.

Electroforming technology: plug & play solution

Electroforming technology allows customization of:

  • Electrode thickness
  • Specific geometries and structures
  • Shape adapted to each cell design

This customization eliminates post-treatment stages, reduces assembly costs, and facilitates direct integration into industrial electrolysis systems.

CFD simulation: Digital optimization for clean energy

The development employed CFD simulation (computational fluid dynamics) to design the optimal structure that maximizes:

  • Efficient gas bubble release
  • Optimized electrolyte flow
  • Enhanced electrocatalytic activity

Validated performance: Results in alkaline electrolyzers

Tests with alkaline electrolyzers (30% KOH, 40°C, Zirfon membrane) demonstrated that NiE3 electrodes significantly outperform traditional expanded nickel meshes:

✓ Notable reduction in cell potential
✓ Higher efficiency at high current densities
✓ Ideal for high-performance systems

Applications in energy transition

This innovation positions high-performance electrolyzers as a viable solution for:

  • Industrial green hydrogen production
  • Renewable energy storage
  • Transport and industry decarbonization
  • Compliance with European Net Zero targets

Impact on the renewable hydrogen market

With Spain positioning itself as a European green hydrogen hub, these technological improvements in alkaline electrolysis reduce the CAPEX and OPEX of electrolyzers, bringing renewable hydrogen closer to competitiveness against fossil fuels.

The combination of increased electrocatalytic activity and improved bubble release positions this technology as a promising breakthrough for making hydrogen production through electrolysis more efficient and economical.

 

The HYPRAEL project has received funding from the Clean Hydrogen Partnership under Grant Agreement No 101101452. This Partnership receives support from the European Union’s Horizon Europe Research and Innovation program, Hydrogen Europe and Hydrogen Europe Research.

 

 

High-pressure hydrogen production-hyprael

HYPRAEL to present at X-SEED project second workshop on high-pressure hydrogen production

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The HYPRAEL project will participate in the X-SEED Project Second Workshop, a key event dedicated to high-pressure H₂ production and end-user applications. The workshop will take place on 3 February 2026 at Snam Facilities in Milan, Italy, with hybrid attendance options available.

About the workshop

This second X-SEED workshop brings together leading European projects and experts working on high-pressure hydrogen technologies. The event will focus on innovative approaches to hydrogen production at elevated pressures and real-world industrial applications where high-pressure H₂ plays a critical role.

HYPRAEL’s participation highlights the project’s pioneering work in pressurized alkaline electrolysis technology, which produces hydrogen directly at pressures exceeding 80 bar, eliminating the need for costly downstream mechanical compression.

Why this matters

High-pressure hydrogen production is essential for reducing the overall cost and energy consumption of green hydrogen systems. By connecting projects like HYPRAEL with end-users and industry stakeholders, the X-SEED workshop facilitates knowledge exchange and accelerates the path toward commercial deployment of advanced hydrogen technologies.

Workshop Highlights

Attendees will have the opportunity to:

Connect with leading projects and experts in hydrogen technologies
Discover the latest developments in high-pressure hydrogen production
Learn how renewable hydrogen is being implemented in industrial applications
Visit Snam facilities (for onsite participants)

Event details

Date: 3 February 2026
Time: 09:00 – 16:30 CET
Location: Snam Facilities, Piazza Santa Barbara 7, San Donato Milanese, Milan, Italy
Format: Hybrid (in-person and online participation available)

Onsite participants will also have the unique opportunity to tour Snam’s hydrogen facilities, gaining firsthand insight into real-world hydrogen infrastructure.

Join the conversation

Whether attending in person or online, this workshop represents a valuable opportunity to explore the future of hydrogen, connect with the European hydrogen community, and discover practical pathways for implementing renewable H₂ in industry.

For agenda details and registration information, visit the X-SEED workshop page.

About HYPRAEL

HYPRAEL is a European innovation project developing advanced pressurized alkaline electrolysis technology for more efficient and cost-effective green hydrogen production. The project aims to produce hydrogen at pressures above 80 bar and temperatures up to 120°C, using sustainable PGM/CRM-free materials.

Funded by the Clean Hydrogen Partnership under Grant Agreement No 101101452, HYPRAEL brings together leading European research institutions and industry partners including Aragon Hydrogen Foundation (coordinator), Fraunhofer IWS, AGFA, VECO, and Syensqo.

For more information:
Website: www.hyprael.eu
LinkedIn: HYPRAEL Project
Twitter/X: @HYPRAEL_EU

 

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HYPRAEL analysis: does Berkeley’s AEM breakthrough threaten or validate alkaline electrolysis (AEL) leadership?

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Experts at HYPRAEL evaluate the impact of UC Berkeley’s new AEM electrolyzer design on durability and cost. Discover why AEL technology remains the most viable and scalable choice for industrial green hydrogen production.

The global clean energy community is buzzing about the recent announcement from UC Berkeley regarding a significant milestone in Anion Exchange Membrane (AEM) electrolyzer technology. The research claims to have mitigated the crucial issue of polymer degradation, potentially lowering manufacturing costs dramatically. This development, while impressive, requires careful strategic context. As specialists in Alkaline Electrolysis (AEL), HYPRAEL recognizes the importance of the research, yet we must underscore the proven maturity of AEL. This article details the key differences, the strategic market response, and why AEL continues to hold the industrial advantage in longevity, tested efficiency, and current scale. Read on for our detailed technological comparison.

AEM’s theoretical cost vs. AEL’s industrial reality

While the cost reduction potential of AEM is appealing, the technology must now transition from lab success to multi-megawatt industrial reliability—a threshold AEL has surpassed for decades. AEL, by utilizing robust and inexpensive liquid electrolytes, avoids the high material costs associated with some membrane systems, making its operational expenditure (OPEX) highly competitive over the long term. This operational stability, essential for continuous industrial output, is the critical advantage AEM must still prove.

Why longevity and efficiency drive HYPRAEL’s AEL strategy

The key metric for industrial-scale deployment is the total cost of ownership (TCO). The long lifespan and established recycling processes of AEL components contribute significantly to its lower TCO. HYPRAEL remains focused on refining AEL’s efficiency curve and further reducing its capital expenditure (CAPEX) to maintain our edge. The Berkeley study, by tackling durability, highlights the fundamental engineering trade-offs inherent in all electrolysis methods.

The hydrogen future: a strong market built on strong competition

HYPRAEL views the progress in AEM as beneficial for the entire green hydrogen sector. Increased competition fosters innovation and validates the global commitment to electrifying fuel production. Our message is clear: the technology is mature, the investment is urgent, and Alkaline Electrolysis (AEL) is the reliable choice for today’s large-scale projects.

Contact HYPRAEL today to discuss how AEL can power your next industrial descarbonization project.

HYPRAEL closes 2025 with key material validation milestones and sets course for 50kW industrial scaling in 2026

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The HYPRAEL consortium, dedicated to developing next-generation Advanced Alkaline Electrolysis (AEL) for highly pressurized hydrogen production, concludes 2025 having successfully achieved crucial milestones in materials research and international visibility. The project, funded by the Clean Hydrogen Partnership under Horizon Europe, is now strategically positioned for the final industrial scaling phase in 2026.

Key technical and scientific achievements in 2025

The year 2025 was defined by the successful completion of Phase 1 (materials development) and the highly successful Phase 2 (screening and testing) of the project. This involved validating innovative electrocatalysts, separators, and polymers capable of withstanding the demanding operational parameters of the HYPRAEL system.

  • High-temperature operation: Laboratory testing confirmed the stability and performance of developed cell components in single cells 10cm2 at temperatures up to 120º, a significant advance beyond the current state-of-the-art for AEL.

  • High-pressure feasibility: Critical data was gathered demonstrating the technical feasibility of in-situ pressurization, reinforcing the project’s goal of reaching 80-100 bar directly within the stack, thereby eliminating energy-intensive downstream mechanical compression processes and achieving near-zero energy loss potential.

Global impact and sustainability

HYPRAEL extended its reach globally, presenting its technical achievements at major international platforms:

  • Market Presence: The consortium presented its technical roadmap and initial results at high-profile events, including Hyvolution Paris (January 2025) and HANNOVER MESSE (May 2025), fostering dialogue with key industrial stakeholders regarding the viability of high-pressure AEL.

  • Sustainable Partnerships: The project’s commitment to sustainability was underscored by the environmental leadership of its partners. The recent CDP A- rating achieved by the consortium partner Syensqo highlights the project’s dedication to a responsible and sustainable supply chain for critical materials.

Vision 2026: the industrial leap

Looking ahead to 2026, the focus shifts entirely to the industrialization and demonstration phases (Phase 3 and 4).

2025 provided the technical proof of concept for our Advanced Alkaline Electrolysis. The data from 120ºC and high-pressure testing are extremely promising. In 2026, we will begin the assembly and rigorous testing of our innovative 50kW stack demonstrator. This will be the definitive validation step for transferring this highly efficient and cost-effective hydrogen production technology to the market.

Alkaline electrolysis: 8% of european publications confirms its technological dominance

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HYPRAEL, a leader in alkaline electrolysis (AEL) solutions for green hydrogen production, welcomes the publication of The Hydrogen Education and Research Landscape report (October 2025). The report highlights the relevance and growing attention the European scientific community is dedicating to alkaline technology.

The analysis, which tracks publications and patents across Europe (EU27, EFTA, and UK) from 2006 to 2025, reveals that alkaline electrolysis accounts for 8% of the total publications identified in the fields of clean hydrogen production, storage, and fuel cells.

The focus shifts to production

This data point is critical, as the study notes a “growing emphasis on publications and patents related to hydrogen production.”

AEL, being the most mature, proven production technology with lower manufacturing costs (as it does not require precious metals as catalysts), is positioned as the most robust and cost-effective solution to meet the increasing demand for green hydrogen at industrial scale.

The report also highlights the presence of alkaline technology in the fuel cell sector, where it accounts for 5% of publications.

HYPRAEL invites media and industry stakeholders to review the full report and visit its website to explore how its state-of-the-art alkaline electrolysers are optimising efficiency and lowering the cost of green hydrogen.