Scientists at Tohoku University have pioneered an affordable hydrogen fuel production method using a novel surface reconstruction strategy for catalysts. This breakthrough in non-noble metal cathodes brings cost-effective clean fuel closer to reality, targeting commercial applications
A team of scientists at the Advanced Institute for Materials Research (AIMR), Tohoku University, announced a significant breakthrough in the quest for affordable and efficient hydrogen fuel production. Their innovative approach focuses on a surface reconstruction strategy to create highly durable and cost-effective catalysts, potentially bridging the gap between laboratory research and large-scale commercial application of clean hydrogen fuel.
The findings, published in the journal Advanced Energy Materials on April 3, 2025, offer a promising pathway to meet the US Department of Energy’s ambitious 2026 hydrogen production cost target.
Overcoming HER inefficiencies with non-noble metals
The hydrogen evolution reaction (HER) holds immense promise for generating clean hydrogen fuel, a crucial component in tackling the climate crisis. However, the inherent inefficiency and slow kinetics of HER have hindered its widespread commercialisation. Traditionally, expensive noble metals are employed as catalysts to accelerate this reaction.
Recognising the need for more affordable alternatives, the Tohoku University research team focused on transition metal phosphides (TMPs), a class of durable and cost-effective non-noble metal compounds known for their catalytic potential.
Fluorine modification unlocks enhanced catalytic activity
The research team’s novel strategy involved modifying cobalt phosphide (CoP) with fluorine. Through meticulous experimentation and advanced analytical techniques, including operando X-ray absorption spectroscopy (XAS) and Raman measurements, they elucidated the mechanism behind the enhanced catalytic performance.
The incorporation of fluorine into the CoP lattice facilitated the formation of phosphorus vacancy sites on the catalyst’s surface. These vacancies act as highly active sites, significantly accelerating the HER process.
Promising performance and cost projections for hydrogen fuel production
The modified catalyst, F-modified CoP, demonstrated exceptional durability, maintaining stable performance for over 300 hours under acidic conditions, a crucial requirement for proton exchange membrane (PEM) electrolysers.
Lead researcher Heng Liu (AIMR) highlighted the economic viability of their approach, stating, “This reconstructed Co is highly active, works in acidic conditions, and can maintain approximately 76 W for over 300 hours. We’re getting close to an affordable method to produce fuel. The calculated cost of using this method is $2.17 per kgH2-1 – just 17 cents over the current production target set for 2026.”
Bridging the gap to commercial application
Beyond laboratory-scale experiments using a three-electrode setup, the researchers extended their findings to commercial-scale PEM electrolysers, demonstrating the practical potential of their innovation. This advancement represents a significant step forward in HER catalyst research, providing a blueprint for the rational design of other high-performance non-noble metal-based cathodes.
Paving the way for a sustainable energy future
“We’re always thinking about the end goal, which is for research to make its way into everyday life,” emphasised Liu. “This advancement brings us one step closer to designing more realistic options for commercial PEM application.”
This research offers a compelling pathway towards affordable and sustainable hydrogen fuel production, potentially playing a pivotal role in the transition to a cleaner energy future.
