200 bar High-Pressure Alkaline Electrolyzer

Rationalizing hydrogen production

Hydrogen production holds immense potential, as hydrogen is widely regarded as a clean and inexhaustible energy source. When burned, it produces only water, resulting in zero emissions of harmful atmospheric pollutants. Although hydrogen is currently used primarily in the chemical, metallurgical, and petroleum industries, it may soon become a competitive alternative to fossil fuels and play a pivotal role in the decarbonization of global economies. While hydrogen itself offers numerous advantages, its production presents a key challenge. Because it is a complex process requiring multi-component installations, the final cost of hydrogen remains relatively high, limiting its broader adoption. Working to simplify hydrogen production is Korneliusz Sierpowski, MSc Eng., from the KOMAG Institute of Mining Technology in Gliwice, who is constructing and testing a high-pressure alkaline electrolyzer - a device designed to produce compressed hydrogen. The research is funded under the European Funds for a Modern Economy 2021–2027 (FENG) program via a Proof of Concept grant awarded by the Foundation for Polish Science.

Hydrogen has long been utilized in metallurgy, chemical processing, and the food industry, where it is used, among other things, to harden vegetable oils into margarine. An emerging market is the automotive sector, particularly the production of vehicles powered by compressed hydrogen. Researchers are currently exploring hydrogen applications for district heating networks as well as its potential for grid-scale energy storage in the form of compressed hydrogen.

The production of green hydrogen relies on a device called an electrolyzer, which uses electrical current to split water molecules into hydrogen and oxygen. As the hydrogen market grows rapidly, electrolyzer technology is evolving alongside it. One primary category is the alkaline electrolyzer, which uses electrodes (a cathode and an anode), an electrolyte, and a separating membrane to generate hydrogen and oxygen as electric current flows between the electrodes.

"I have been developing this electrolyzer design as part of my research interests for some time, and securing a grant to continue this work - specifically to achieve high operating pressure - is a dream come true," says Korneliusz Sierpowski, MSc Eng. "The first innovation in the electrolyzer I am building lies in its electrodes, which are made from readily available materials with low nickel content. If the hydrogen economy experiences a massive boom, nickel availability could become constrained, driving up prices and consequently inflating the cost of electrolyzers themselves," explains the researcher.

However, that is not the only advantage. The electrolyzer developed by Mr. Sierpowski will produce hydrogen at a pressure of 200 bar. This capability bypasses the first stage of hydrogen compression, eliminating the need for several compression components typically required in hydrogen production plants. "The simple design of our electrolyzer, coupled with the ability to eliminate components currently required in hydrogen production systems, will reduce capital expenditure, directly driving down the cost of hydrogen. Furthermore, producing hydrogen with this system requires less electrical energy, further lowering costs while providing a more environmentally friendly solution," assures the engineer.

The project is being conducted in collaboration with an industrial partner, SBB—a company operating as a hydrogen solution integrator. "Under the Proof of Concept grant, we aim to demonstrate the commercial potential of our device. If this phase is successful, it will undoubtedly open multiple pathways for industrial implementation," concludes Mr. Sierpowski.

Korneliusz Sierpowski, MSc Eng., graduated from the Faculty of Mechanical and Power Engineering at Wrocław University of Science and Technology. His primary research interests include hydrogen energy, numerical modeling, and unmanned aerial vehicles (UAVs). He has gained scientific expertise through several research projects in power engineering (conducted at Wrocław University of Science and Technology and the KOMAG Institute of Mining Technology) and national defense (at the General Tadeusz Kościuszko Military University of Land Forces). In 2024, he received the Best Young Researcher Award at the National Electronics Conference (23rd KKE) for his paper on using hydrogen as a power source for unmanned aerial vehicles.