Power to Hydrogen (P2H2) and Repsol have completed a pilot program validating P2H2’s hybrid anion exchange membrane (AEM) electrolysis technology for large-scale green hydrogen production, with results that the companies say met or exceeded key performance targets across efficiency, flexibility, and durability.

The pilot was conducted through Repsol’s All4Zero industrial innovation hub and evaluated P2H2’s commercial-scale AEM stack across more than 1,250 hours of parametric and durability testing, including operation under simulated variable load profiles. The test protocol included repeated cycling between 40% and 100% load and operation across pressures from 2 to 30 bar.

The stack recorded irreversible degradation of approximately 2 mV/kHr over the testing period, with average cell voltage described as virtually unchanged between the start and end of the test. Based on these results, P2H2 projects system lifetimes exceeding 50,000 hours. Hydrogen purity reached up to 99.9% at 30 bar operating pressure. The system also resumed testing without consequence following an unplanned facility power outage.

Using the US Department of Energy’s H2A-Lite analysis framework with Repsol-specific inputs, P2H2 projects a levelized cost of hydrogen of approximately €3.86/kg, representing around a 16% reduction versus incumbent electrolyzer technologies. Under optimized renewable energy scenarios with hybrid power purchase agreements, the company said costs could reach approximately €2.82/kg.

“This pilot proves what we’ve long believed: that AEM electrolysis can deliver PEM-like performance at a fundamentally lower cost structure,” said Dr. Paul Matter, Founder and CEO of Power to Hydrogen. “With Repsol’s rigorous testing framework and real-world operating conditions, we’ve demonstrated the durability and efficiency that the market has been waiting to see from AEM. This is commercial-scale hardware, stress-tested under the conditions that matter to industrial buyers.”

Berta Moreno, Senior Scientist at Repsol, said: “Through our All4Zero accelerator, Repsol is committed to identifying and validating the technologies that will be essential to decarbonising industrial operations at scale. Power to Hydrogen’s results demonstrate meaningful progress toward the performance thresholds required for large-scale renewable hydrogen deployment.”

The companies are exploring a larger-scale demonstration at the 500 kW to megawatt level. P2H2 has stated it is actively deploying systems at this scale, including ongoing projects at the Port of Antwerp-Bruges, Belgium, and with SINTEF in Norway. Repsol has set a target of 600–800 MW of renewable hydrogen capacity by 2030.

Source:  Hydrogentechworld