Hydrogen Production & Fuel Cell Technology
Hydrogen technology research is focused on developing and improving technologies for the production, storage, transportation, and use of hydrogen as a clean energy carrier. Hydrogen is a versatile fuel that can be used to generate electricity, power vehicles, and heat homes and businesses.
PI-KEM is playing an important role in the development of hydrogen fuel cell technology by providing researchers and developers with the materials and equipment they need to create new and innovative fuel cells. Our cross-discipline Business Development Team are well placed to provide advice and guidance on a range of project goals, from synthesis and printing of electrode materials, to construction of novel fuel cell designs. To discuss your fuel cell research objectives, complete our enquiry form or contact our experts directly. Click here to review our product offerings for fuel cell research.
Fuel cells are a key technology that utilise a continuous supply of hydrogen fuel, and they form a cornerstone of clean energy goals. Sold oxide fuel cells (SOFCs) convert hydrogen directly into electricity, through the simultaneous oxidation of hydrogen and reduction of oxygen. These cells function with high efficiency, typically reaching 40–60% electrical efficiency, and out-performing conventional combustion-based energy generation. By integrating fuel cells into combined heat and power (CHP) systems, useful heat is captured alongside electricity, enabling overall efficiencies above 80%.
Hydrogen technology research is a complex and challenging field but, driven by the need to decarbonise the energy sector and reduce greenhouse gas emissions, it has the potential to revolutionise the way we produce and consume energy. By developing new and more efficient ways to produce, store, and use hydrogen, researchers are paving the way for a more sustainable future - the hydrogen economy.
SOFC Benefits and Applications
Besides their efficiency, SOFCs feature stability, quiet operation, fuel flexibility and a modular design to facilitate scaling. These assets make them ideal for use in a variety of applications, including:
- Electric vehicles, aerospace, shipping transportation (trucks, ships etc)
- Stationary power plants, back-up energy generation
- Stabilising renewable power grids
- Energy storage
Reversible solid oxide cells (rSOC) can operate alternatively as a solid oxide fuel cell (SOFC) or as a solid oxide electrolyser cell (SOEC). In SOEC mode, surplus renewable electricity is used to split water into hydrogen and oxygen, storing clean energy in the form of hydrogen. When demand rises, the same system can switch to SOFC mode to regenerate electricity. While still in the pilot stage, this is a promising route to balance intermittent solar and wind power, overcoming one of the prominent hurdles to widespread use of renewable energy sources.
This technology remains a focus of research efforts to move it from test scales to commercial usage, with emphasis on optimised efficiency, improved material durability, and lower costs. PI-KEM can provide high-quality electrode, interconnect and electrolyte materials, as well as ceramic components and high temperature conductive adhesives, sealants and coatings designed to support work on improving durability and efficiency.
Challenges Facing the Hydrogen Economy
Hydrogen is an excellent energy carrier, with the capacity to fundamentally improve the fields of clean and renewable energy. However, the nature of hydrogen creates significant barriers to adoption, including: extraction and purification, storage and transport, and material durability.
Hydrogen Extraction
One of the key challenges facing hydrogen technology is the cost of production and the associated greenhouse gas emissions. Fuel cells are valued for producing electricity without carbon emissions, making them key to the sustainable energy goals held by most major global economies. The hydrogen fuel utilised in SOFCs is abundant in nature but not freely available, requiring intensive extraction from compounds such as water or natural gas before use.
Today, most hydrogen is produced from fossil fuels via steam methane reforming, releasing CO₂ emissions into the atmosphere. This so-called grey (or blue, if carbon capture is applied) hydrogen conflicts with the goals of a clean energy transition. Achieving true decarbonisation relies on green hydrogen, generated via electrolysis powered by renewable energy sources, such as wind or solar. However, this process remains energy- and cost-intensive, and scaling it to global demand is a major challenge. Competitiveness depends on reducing costs and improving efficiency across the production chain, to enable green hydrogen to rival blue and grey pathways.
Storage and Transportation
Another challenge facing hydrogen technology is the development of safe and efficient storage methods. As hydrogen is a low density gas, its storage and transportation adds barriers into the supply chain. To store and transport it efficiently, hydrogen must be compressed, liquefied, or converted into carriers such as ammonia or liquid organic hydrogen carriers (LOHCs). Each method consumes energy and adds extra layers of complexity. High-pressure and cryogenic systems also face durability and safety challenges, as hydrogen is highly flammable and prone to leakage. Developing large-scale refuelling networks, pipelines, and storage facilities will demand global coordination and significant investment. Research focuses on developing new materials and sealants that can store and transport hydrogen more efficiently and safely.
Current research focuses on developing new materials and sealants that can store and transport hydrogen more efficiently and safely. At PI-KEM, we have an expansive supplier network, allowing us to provide a broad range of materials for advanced applications. Contact our materials experts to discuss your material specification requirements.
Material Durability
SOFCs and electrolysers can face materials durability challenges from high operating temperatures, redox cycling, and chemical stress. Yet SOFCs’ high-temperature operation allows internal reforming of hydrogen-containing fuels such as ammonia, natural gas, and other hydrocarbons — offering valuable fuel flexibility. The trade-off is that impurities like sulphur or chlorine can poison nickel-based anodes, reducing efficiency and lifespan. While pure hydrogen operation mitigates degradation, producing and maintaining high-purity fuel adds cost and energy demand. The future of SOFCs and electrolysers depends on balancing performance, durability, scalability, and fuel purity.
To support this, PI-KEM can supply a spectrum of electrode, interconnect, protonic conductor and electrolyte powders, with novel compositions and stoichiometries available to facilitate research into durability and efficiency.
Despite these challenges, hydrogen technology has the potential to play a major role in our future energy mix. Research is focused on developing new and more efficient ways to produce, store, and use hydrogen, as well as developing new applications.
Current Hydrogen and SOFC Research Focuses
- Materials development: Improving the performance, durability, and cost-effectiveness of fuel cell materials is essential for their widespread commercialisation. Researchers are developing new materials for electrodes, electrolytes, and other components, as well as new methods for manufacturing and assembling fuel cells. PI-KEM can supply a broad range of active materials and ceramic components for fuel cell research.
- System design and integration: Fuel cells need to be integrated with other components, such as hydrogen storage systems and power converters, to create complete and efficient systems. Researchers are developing new system designs and control strategies to optimize the performance of fuel cell systems for a variety of applications. Advanced ceramic components and high temperature adhevsives, sealants and coatings are important for designing systems to operate effiicenty in the high temperatures of a fuel cell.
- Fuel cell applications: Fuel cells can be used in a wide range of applications, including transportation, power generation, and energy storage. Researchers are continuously developing new fuel cell systems to evolve into more for specialised applications, such as electric vehicles, buses, trucks, ships, and stationary power plants. Researchers are developing new fuel cell technologies that are more efficient, durable, and less expensive than existing fuel cells and far less polluting than traditional internal combustion engines.
- Production: Researchers are developing new methods for producing hydrogen from renewable energy sources and have developed new catalysts that can produce hydrogen from water more efficiently and at lower cost. This will help to make hydrogen a more sustainable and carbon-free energy source. High-temperature electrolysis is more efficient than traditional electrolysis technologies and can be used to produce hydrogen from renewable energy sources.
UK & International Research Projects
- University of Sheffield researchers are working with industry to produce new hydrogen fuels for the aviation sector utilising a hydrogen electrolyser
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- The Hydrogen Materials Group at The University of Birmingham are investigating the development of Solid Oxide Fuel Cell (SOFC) power systems.
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- The Institut Carnot, Energies du Future (France) research is looking at fuel cells and how energy losses can be minimised.
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- TUM Electrochemistry department research is developing new catalysts based on platinum group metals to stabilise the fuel cell reactions and improve efficiency in fuel cells.
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