Balancing Energy and Material Efficiency in Green Hydrogen Production via Water Electrolysis

Green hydrogen is increasingly regarded as a pivotal solution in achieving “net zero by 2050” in carbon neutrality across various sectors and industries. Ambitious decarbonisation roadmaps largely depend on the successful deployment of electrolysis technologies. Among these, Proton Exchange Membrane Electrolysis (PEMEL) stands out for its efficiency, compact design, and adaptability to intermittent renewable power sources. PEMEL is gradually being commercialised, and considerable uncertainty remains regarding its future environmental performance at a plant level. Therefore, future PEMEL cells should be life cycle engineered with a focus on improving materials efficiency by investigating enhanced electrochemical catalysts, membranes, and electrodes for an improved membrane electrode assembly (MEA). In this study, we simulate a 10MW PEMEL plant, identify key operational parameters and evaluate future MEA development scenarios to assess their impact on energy consumption, material utilisation, and system durability. Our findings shed light on the potential trade-offs between energy and material efficiency, providing valuable insights to mitigate environmental hotspots. By focusing on these trade-offs, this work contributes significantly to the ongoing efforts to improve the environmental and operational performance of PEMEL plants.