Smoltek hydrogen is paving the way for a sustainable future as we are making production of green hydrogen viable. By introducing a porous transport electrode (PTE) for PEM electrolyzers that increases the active surface area by 30 times and reduces the need for iridium by up to 95 percent, while maintaining high performance, we are enabling the scale-up of next generation PEM electolyzers.

Partner with us – for cost leadership

Smoltek Hydrogen can create a highly attractive market position based on substantial cost leadership as we have developed a solution to the most critical obstacle limiting the large-scale adoption of green hydrogen: the extreme scarcity and high cost of iridium catalyst used in PEM electrolyzers.

Our innovative PTE technology succeeds where competitors have struggled in trying to refine the coating of the membrane (CCM). By taking a Catalyst Coated Substrate (CCS) approach – coating of the metallic substrate instead of the plastic membrane – we now have the solution for cost-effective fossil-free hydrogen production.

The Iridium Challenge

Iridium’s scarcity and cost pose a major barrier to scaling green hydrogen production. Global output is limited to just 7–8 tons per year—enough for only 4–5 GW of PEM electrolyzer capacity at today’s usage rates (1–2 mg/cm²). That’s just 2% of projected 2030 demand.

Conventional Catalyst Coated Membranes (CCM) waste much of this precious metal, as only surface atoms are active while the rest remain unused. At 2 mg/cm², iridium costs reach $60 million per gigawatt. Reducing usage to 0.1 mg/cm² would cut that to just $3 million—a critical step toward economic viability.

Despite years of research, industry has stalled at 0.5 mg/cm²—still five times above the target. A breakthrough is needed.

Smoltek Hydrogen offers a solution: Catalyst Coated Substrate (CCS) using our proprietary carbon nanofiber technology. By increasing the active surface area 30-fold, we enable nearly full catalyst utilization and achieve the 0.1 mg/cm² milestone—unlocking scalable, cost-effective green hydrogen.

Three times smaller without compromising capacity

Smoltek’s advanced carbon nanostructure technology has a unique potential to enable more cost-efficient production of fossil-free hydrogen. PEM electrolyzers, specifically designed for intermittent energy supply, use a large amount of very rare and expensive catalyst particles (iridium) that today are used inefficiently – whereas Smoltek’s anode-side cell material technology makes maximum use of the catalyst particles. The result is 2-3 lower investment costs for electrolyzers in hydrogen plants thanks to decreased electrolyzer size.

Carbon nanostructures in the hydrogen industry

Our main objective is to develop robust solutions for industrially relevant catalyst coatings in the energy conversion sector for the future. We build on our experience to scale up nanostructures developed for the semiconductor industry to also incorporate thin films that can catalyze effectively the reactions needed in gas diffusion electrodes for water electrolysis. The goal is to offer our customers superior properties in terms of stability and activity.

A huge green H2 (hydrogen) market is developing in the coming years. Five sectors will consume massive amounts of green hydrogen:

• Fuel cells in electric vehicles when batteries are not suitable
• Synthetic fuels for marine applications
• Replacing today’s H2 in agriculture fertilizer
• Fossil-free steel works
• Heating in cement production

With new technology, we intend to grow a substantial business in the hydrogen ecosystem

Reduce the need for expensive iridium and platinum:

• Reduce the size of hydrogen plants
• Cheaper to manage the intermittent power from wind, water, and solar plants

Skyrocketing demand for electrolyzers—“The H2 producer”

Green hydrogen is produced by electrolysis. Simply put, that is running electricity through water and gathering the released hydrogen. The apparatus in which this is done is called an electrolyzer.

Today, there are mainly two different electrolysis techniques for the production of hydrogen; Alkaline electrolysis (ALK) and Proton Exchange Membrane (PEM) electrolysis. ALK has been around the longest but the technology faces difficulties as it cannot be quickly adapted to varying input from green electricity, such as wind and solar. PEM on the other hand is more flexible and can handle the variations from the intermittent power sources.

The PEM technology’s benefits also include high efficiency, minimal upkeep requirements, and rapid startup times. It can also lower costs thanks to being able to produce more hydrogen when electricity is cheaper. These are the main reason why PEM electrolyzers are anticipated to expand at the highest rate when the industry will scale up hydrogen production.

The critical component of a PEM electrolyzer is the cell. It is the unit where the electricity in contact with water becomes hydrogen and oxygen. Each hydrogen production unit has vast numbers of these. Thus, the rapid growth of the production capacity of green hydrogen implies that the demand for electrolyzer cells will skyrocket.

With clever use of carbon nanofibers, we can reduce the use of rare and expensive noble metals by 50–70 percent while doubling or tripling the active surface area of the proton-exchange membrane (PEM) in electrolyzers and fuel cells.

And this will enable the green hydrogen revolution!

Hydrogen market – market for electrolyzers

1. Fuel cells in electric vehicles when batteries are not suitable

Electric heavy-duty vehicles are the key to fossil-free transport. When batteries would not provide a long enough range, fuel cells are the alternative. The vehicle is loaded with hydrogen, which the fuel cell transfers into electricity. This will be used for heavy-duty trucks, coaches, long-range passenger vehicles, and trains.

2. Synthetic fuels for marine applications

For long distances, heavy marine transports synthetic fuel is a convenient way to make the transports green. Existing combustion engines are run on synthetic fuels produced from green H2. Also, biofuels, lithium-ion batteries, and fuel cells will be used to make the sector fossil-free. Still, synthetic fuels are considered most attractive, given that the cost of producing hydrogen can be reduced.

3. Replacing today’s fossil hydrogen in agriculture fertilizer

Ammonia is the second most commonly produced chemical in the world, and it is derived from hydrogen. More than 80 percent is used as feedstock for fertilizer. The rest are used in making paint, plastic, textiles, explosives, and other chemicals. Ammonia production in 2018 generated around 500 million tons of carbon dioxide, where a large part comes from hydrogen produced by steam methane reforming. Making this from green hydrogen instead implies an immense growth of the electrolyzer market.

4. Fossil-free steel works

New steel works are being built all around Europe, something that has not happened for hundreds of years. The new steelworks will be using green hydrogen instead of fossil gas. Each ton of steel produced today is estimated to emit 2.2 tons of carbon dioxide—equating to about 11 percent of global carbon dioxide emissions. In Sweden, two well-known examples are the HYBRIT project run by SSAB, LKAB, and Vattenfall, and H2 Green Steel, a new ambitious company building new steelworks in Sweden and Iberia. Similar projects are seen, for instance, in Germany. For each new steelworks, a new large-scale hydrogen plant is being built.

5. Heating in cement production

Green hydrogen can be used for high-grade industrial heating in, for example, the cement industry, which accounts for 8 percent of global carbon dioxide emissions. Emissions can be reduced by a third by using green hydrogen to heat the cement kilns. (The remaining two-thirds come from the chemical reaction that produces cement and must be captured and stored or reduced by other means.)

Rapid increase in demand for green hydrogen

Green hydrogen means that electricity from renewable sources is used, like wind, water, and solar energy. The wind and solar power capacity are planned to be built up at a large scale globally to match the demand. The large volume production combined with the technology running down the experience curve indicates an attractive cost per kilowatt from green electricity. For example, wind power is increasingly being produced in large offshore wind farms in the coming decade. Wind power already reaches a lower cost per kilowatt than new nuclear power.

Carbon nanostructures in hydrogen

Currently, we focus on improving the electrochemical cell in PEM electrolyzers and fuel cells. The cell enables the conversion of electricity into hydrogen and vice versa. Thus, it’s a key component in storing and transmitting renewable energy and decarbonizing industry, transportation, and heating.

Learn more

Recommended reading for you who want to learn more about Smoltek Hydrogen and our electrolyzer technology: