Advanced PEM Electrolysis For Cost-Effective Green Hydrogen Production

Abstract

Green hydrogen produced via water electrolysis powered by renewable energy is widely recognized as a cornerstone of the global energy transition. However, the high cost of proton exchange membrane (PEM) electrolysis remains a significant barrier to commercial viability. This paper presents advances in PEM electrolyzer design incorporating a novel IrRuOₓ bimetallic anode catalyst and a reinforced composite proton exchange membrane to simultaneously improve efficiency and durability. The advanced PEM system achieved an energy efficiency of 82.3% at 2 A/cm² current density, representing a 15.7% improvement over conventional systems. Accelerated stress testing demonstrated a degradation rate of 4.8 µV/h, approximately three times lower than conventional Nafion-based systems (14.5 µV/h), projecting a membrane lifetime exceeding 80,000 hours. Techno-economic analysis indicates that the advanced system reduces the levelized cost of hydrogen from $5.5/kg to $3.8/kg, with further reductions to below $2.5/kg achievable at scale with projected renewable electricity costs. These results demonstrate a viable pathway toward meeting the U.S. Department of Energy's Hydrogen Shot target of $1/kg by 2031.