Materials for Green Hydrogen Production 2026-2036: Technologies, Players, Forecasts
Components for electrolyzer stacks including AEL, AEMEL, PEMEL & SOEC. Granular 10-year market forecasts for electrolyzer components. Review of incumbent & advanced materials, component designs, manufacturing technologies, key players
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IDTechEx forecasts substantial growth in the electrolyzer component sector, projecting a market value of US$10.1 billion by 2034. This is attributed to the expanding green hydrogen industry, where electrolyzers are indispensable. This comprehensive IDTechEx report delves into the current and prospective materials and components utilized in the four main water electrolyzer technologies: alkaline electrolyzer (AEL/AWE/ALK), proton exchange membrane electrolyzer (PEMEL), anion exchange membrane electrolyzer (AEMEL), and solid oxide electrolyzer (SOEC). In addition, granular 10-year market forecasts, quantifying material and component demand intonnes, square meters (m2), and US$ million annually are presented for the four electrolyzer stacks.
The need for green hydrogen and advanced electrolyzer technologies
The global transition towards hydrogen use in industrial, transport, and energy sectors is accelerating, driven by a concerted effort from governments and industries to decarbonize sectors where direct electrification is challenging. Green hydrogen, produced via renewable-powered water electrolysis, has become a leading solution, with significant investments aimed at establishing gigawatt-scale production capacities by 2030. The pivot to green hydrogen not only offers a viable path to reduce emissions in heavy industry and transportation but also enhances energy security and creates new market opportunities in energy storage and sector coupling.
Source: IDTechEx
Critical role of materials and components in electrolyzers
At the heart of the green hydrogen revolution lies the evolution of materials and components within electrolyzer technologies. Advancements in this area are pivotal, aiming to boost electrolyzer efficiency, extend longevity, and mitigate reliance on scarce materials. For example, innovations in PEMEL technology, such as catalysts with reduced iridium content, could significantly alleviate supply chain vulnerabilities associated with iridium's limited availability.
This IDTechEx report provides a comprehensive analysis of the key materials and components across the four electrolyzer technologies, emphasizing both established solutions and prospective advancements. Components analyzed include membranes, catalysts, electrodes, porous transport layers (PTL), gas diffusion layers (GDL), bipolar plates, coatings, gaskets, and end plates, offering insights into their current and future states. Manufacturing methods and potential innovations are also discussed. Furthermore, the report includes extensive lists of stack, material and component suppliers and provides commercial case studies of materials and components.
The focus of this report is on the cell to stack level of electrolyzers. Source: IDTechEx
The AEL is a mature and established technology. It operates using a liquid alkaline solution (typically KOH) and a porous diaphragm to segregate the half-cell chambers. Its reliance on accessible materials like nickel and stainless steel is a stable trend, which is anticipated to persist. Currently, AEL systems vary between finite-gap and zero-gap configurations, but the industry is gravitating towards the latter, which incorporates porous transport layers (PTLs) for improved efficiency.
AEL manufacturers exhibit diverse designs that are dependent on the operational mode (atmospheric versus pressurized) and cell architecture. This report provides an in-depth examination of material choices and the architectural evolution of the AEL stack, showcasing examples of cutting-edge stacks. It also highlights key innovation priorities and improvements that could be made in existing components. While many AEL have brought stack production in-house, they still depend on external suppliers for numerous components, revealing substantial opportunities for innovation in catalysts and cell configurations within this established technology.
Proton exchange membrane electrolyzer (PEMEL) - management of scarce materials
PEMEL technology has risen in popularity due to its superior efficiency, compact stack size, and flexible operational capabilities, making it ideal for pairing with intermittent renewable energy sources. Despite a trend towards standardization of materials in PEMEL stacks, ongoing innovations continue, especially in anode catalyst development. New catalysts demonstrate comparable catalytic activity with less iridium usage, hence decreasing the materials loading in g/kW, leading to cost reductions.
The report examines various material choices and innovations within PEMEL stacks, from advancements in proton exchange membrane thinning to innovative titanium bipolar plate coating technologies. It details advanced commercial PEMEL designs and key priorities for innovation. Overall, significant enhancements in PEMEL stacks are achievable through novel bipolar plate materials and coatings for the catalyst-coated membrane (CCM), for example.
The AEMEL is a newer, up-and-coming technology seeking to combine AEL's abundant materials with the high efficiency of PEMEL stacks. Rapid advancements in the field are evident, with companies like Enapter leading the way in commercial MW-scale systems. The report indicates various material developments, with academic and commercial entities focusing on membranes and catalysts, given the standardization of other components derived from AEL or PEMEL technologies. As a nascent technology, AEMEL has the unique advantage of integrating lessons from AEL and PEMEL, positioning it for innovation.
Solid oxide electrolyzer (SOEC) - high-temperature ceramic innovation
The SOEC, although newer and with fewer market participants than AEL and PEMEL, is benefiting from cross-innovation in the solid oxide fuel cell (SOFC) space since SOFC stacks can be operated reversibly and use very similar materials to SOEC. Certain ceramic cell components are well-established due to their application in SOFCs. However, electrode-electrolyte assemblies present an active frontier for development, with significant variations in cell design and materials among stack providers. The report delves into these nuances, exploring the various cell designs. These range from metal- to electrode-supported and utilize diverse ceramic materials, highlighting the potential for material innovation in this high-temperature electrolyzer technology.
Granular 10-year market forecasts segmented by materials and components for AEL, PEMEL, AEMEL & SOEC
To identify the expanding prospects of the materials and components sector in the water electrolyzer industry, IDTechEx offers granular 10-year market forecasts. These projections are segmented by raw materials - such as stainless steel, titanium, and platinum group metals - and by components, including membranes and bipolar plates, across AEL, PEMEL, AEMEL, and SOEC electrolyzer technologies. Quantitative forecasts are provided in terms of tonnes, square meters (m²), and US$ million on an annual basis. Additionally, the report provides a high-level cost analysis of AEL, PEMEL, AEMEL, and SOEC stacks, breaking down the costs associated with each component.
Key aspects of this report
This report provides the following information:
- Review of all major components in the four water electrolyzer stacks: AEL, AEMEL, PEMEL and SOEC. Components discussed include catalysts & electrodes, membranes/electrolytes, porous transport layers (PTLs), gas diffusion layers (GDLs), membrane electrode assembly (MEA), bipolar plates, gaskets & stack assembly components.
- Review of the incumbent materials and components used in the four major electrolyzer technologies.
- Discussion of the key challenges associated with incumbent materials.
- Advanced and innovative materials that can alleviate challenges.
- Overview of manufacturing methods for electrodes, bipolar plates and catalyst coated membranes (CCM).
- Summaries of all material and component options available for the four electrolyzer stacks.
- Analysis of key innovation priorities and potential for cost reductions across the four electrolyzer stacks.
- Case studies and commercial examples of companies supplying materials and developing new materials or manufacturing methods.
- Comprehensive lists of electrolyzer stack manufacturers and material suppliers.
- Total electrolyzer stack costs broken down by component forAEL, PEMEL, AEMEL and SOEC stacks.
- Granular 10-year market forecasts by component and material type for AEL, PEMEL, AEMEL and SOEC stacks. Forecasts include component/material demand in tonnes per annum (tpa) and 1000's of m2 per annum, as well as market values for components in US$M.
- Discussion of manufacturing and wider supply chain issues.
IDTechEx's hydrogen research portfolio
This report includes entirely new content on the materials and components for water electrolyzers, drawing on IDTechEx's existing research in green hydrogen production and fuel cells. Further information on the hydrogen economy, low-carbon hydrogen production, fuel cells, fuel cell mobility sectors can be found in these reports.
| Report Metrics | Details |
|---|---|
| CAGR | IDTechEx forecasts the water electrolyzer component market to grow at a CAGR of 25% for the 2025-2036 period. |
| Forecast Period | 2025 - 2036 |
| Forecast Units | Tonnes per annum (tpa), thousands of m2 per annum, US$ millions (US$M) |
| Regions Covered | Worldwide |
| Segments Covered | Catalysts & electrodes, membranes/electrolytes, porous transport layers (PTLs), gas diffusion layers (GDLs), membrane electrode assembly (MEA) methods, bipolar plates, gaskets & stack assembly components for AEL, AEMEL, PEMEL & SOEC electrolyzer stacks. |
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Further information
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| 1. | EXECUTIVE SUMMARY |
| 1.1. | Overview of electrolyzer technologies |
| 1.2. | Water electrolyzer technology comparison - current density & voltage (1) |
| 1.3. | Water electrolyzer technology comparison - current density & voltage (2) |
| 1.4. | AEL materials & components summary |
| 1.5. | AEL materials & components summary |
| 1.6. | AEL system suppliers by type (atmospheric, pressurized, advanced) |
| 1.7. | AEL component supply chain |
| 1.8. | AEL - electrodes & catalysts summary |
| 1.9. | AEL - porous diaphragm summary |
| 1.10. | AEL - bipolar plate (BPP) summary |
| 1.11. | AEL - porous transport layer (PTL) summary |
| 1.12. | PEM electrolyzer component summary |
| 1.13. | PEMEL materials & components summary |
| 1.14. | PEMEL stack suppliers |
| 1.15. | PEMEL component supply chain (1/2) |
| 1.16. | PEMEL component supply chain (2/2) |
| 1.17. | PEMEL - proton exchange membrane summary |
| 1.18. | PEMEL - catalysts (anode & cathode) summary |
| 1.19. | PEMEL - CCM / MEA summary |
| 1.20. | PEMEL - porous transport layer (PTL) & gas diffusion layer (GDL) summary |
| 1.21. | PEMEL - bipolar plate (BPP) & coating summary |
| 1.22. | AEMEL materials & components summary |
| 1.23. | AEMEL stack & anion exchange membrane suppliers |
| 1.24. | AEMEL - anion exchange membrane summary |
| 1.25. | AEMEL - electrodes / catalysts and CCM / MEA summary |
| 1.26. | AEMEL - bipolar plates, porous transport layers, gas diffusion layers |
| 1.27. | Gaskets for AEL, PEMEL & AEMEL |
| 1.28. | SOEC materials & components summary |
| 1.29. | SOEC materials & components summary |
| 1.30. | SOEC & SOFC system suppliers |
| 1.31. | SOEC component supply chain |
| 1.32. | SOEC - electrode electrolyte assembly (EEA) (1) |
| 1.33. | SOEC - electrode electrolyte assembly (EEA) (2) |
| 1.34. | SOEC - interconnects, coatings & contact layers summary |
| 1.35. | SOEC - gaskets & sealants summary |
| 1.36. | End plates for electrolyzers (AEL, PEMEL, AEMEL, SOEC) |
| 1.37. | Annual electrolyzer demand by technology (GW) |
| 1.38. | Electrolyzer stack cost forecasts by technology (US$/kW) |
| 1.39. | Electrolyzer stack cost forecasts by component (%) |
| 1.40. | Annual electrolyzer components market by technology (US$M) |
| 1.41. | AEL - components market forecast (US$ millions) |
| 1.42. | PEMEL - components market forecast (US$ millions) |
| 1.43. | SOEC - components market forecast (US$ millions) |
| 1.44. | AEMEL - components market forecast (US$M) |
| 1.45. | Access More With an IDTechEx Subscription |
| 2. | INTRODUCTION |
| 2.1. | Introduction to the hydrogen value chain |
| 2.1.1. | State of the hydrogen market today |
| 2.1.2. | Major drivers for hydrogen production & adoption |
| 2.1.3. | Key legislation & funding mechanisms driving hydrogen development |
| 2.1.4. | The colors of hydrogen |
| 2.1.5. | Hydrogen value chain overview |
| 2.1.6. | Why is green hydrogen needed? |
| 2.1.7. | Typical green hydrogen plant layout (1) |
| 2.1.8. | Typical green hydrogen plant layout (2) |
| 2.1.9. | Green hydrogen: Main water electrolyzer technologies |
| 2.1.10. | Cost comparison of different types of hydrogen |
| 2.1.11. | Overview of hydrogen storage |
| 2.1.12. | Overview of hydrogen distribution |
| 2.1.13. | Overview of hydrogen applications |
| 2.1.14. | Fuel cell technologies - overview |
| 2.1.15. | Automotive PEMFC demand far exceeds that of stationary applications |
| 2.1.16. | Hydrogen purity requirements |
| 2.1.17. | European hydrogen market - major developments |
| 2.1.18. | European hydrogen market - major setbacks & challenges |
| 2.1.19. | US hydrogen market drivers - pre-2025 |
| 2.1.20. | US hydrogen market challenges - 2024 and 2025 |
| 2.1.21. | Outlook on the low-carbon hydrogen industry in the US |
| 2.1.22. | Outlook on the low-carbon hydrogen industry globally |
| 2.2. | Overview of green hydrogen & water electrolysis technologies |
| 2.2.1. | Monopolar vs bipolar electrolyzers |
| 2.2.2. | Overview of electrolyzer technologies |
| 2.2.3. | Overview of electrolyzer technologies & market landscape |
| 2.2.4. | Electrolyzer cells, stacks and balance of plant (BOP) |
| 2.2.5. | Electrolyzer balance of plant (BOP) layout example |
| 2.2.6. | Electrolyzer BOP & typical system boundaries |
| 2.2.7. | Comparison of electrolyzer performance characteristics |
| 2.2.8. | Pros & cons of the four main electrolyzer technologies |
| 2.2.9. | Factors to consider in electrolyzer choice |
| 2.2.10. | Cost challenges in green hydrogen production |
| 2.2.11. | Why innovate electrolyzer materials & components? |
| 2.3. | Electrochemistry basics |
| 2.3.1. | Importance of active & stable electrocatalysts |
| 2.3.2. | Electrocatalyst activity metrics |
| 2.3.3. | Electrocatalyst stability & efficiency metrics |
| 2.3.4. | Origin of the volcano plot in electrocatalysis |
| 3. | ALKALINE ELECTROLYZER (AEL) MATERIALS & COMPONENTS |
| 3.1. | Overview of alkaline electrolyzers & component supply chain |
| 3.1.1. | Alkaline water electrolyzer (AEL) - brief historical background |
| 3.1.2. | Alkaline electrolyzer (AEL) plant - operating principles |
| 3.1.3. | Classifications of alkaline electrolyzers |
| 3.1.4. | Atmospheric vs pressurized alkaline electrolyzers |
| 3.1.5. | Alkaline water electrolyzer (AEL) - modern commercial cell & stack designs (1) |
| 3.1.6. | Alkaline water electrolyzer (AEL) - modern commercial cell & stack designs (2) |
| 3.1.7. | Next-gen alkaline electrolyzer stack design |
| 3.1.8. | Electrolyzer OEM's perspectives on stack component innovation |
| 3.1.9. | US DOE technical targets for AEL |
| 3.1.10. | AEL materials & components summary |
| 3.1.11. | AEL materials & components summary |
| 3.1.12. | Evolution of alkaline electrolyzer cell electrodes & porous transport layers |
| 3.1.13. | Key innovation focuses for AEL improvement |
| 3.1.14. | AEL materials & components supplier summary |
| 3.1.15. | AEL system suppliers by type (atmospheric, pressurized, advanced) |
| 3.1.16. | AEL component supply chain |
| 3.1.17. | AEL membrane & cell frame |
| 3.1.18. | AEL gasket / seal suppliers |
| 3.1.19. | AEL electrodes, catalysts & PTL/GDL suppliers |
| 3.1.20. | AEL electrodes, catalysts & PTL/GDL suppliers |
| 3.1.21. | AEL bipolar plate suppliers |
| 3.2. | AEL catalysts & electrodes |
| 3.2.1. | AEL - electrodes & catalysts summary |
| 3.2.2. | Zero-gap electrode configuration in alkaline electrolyzers |
| 3.2.3. | De Nora's zero-gap cell design |
| 3.2.4. | Substrates for alkaline electrolyzer electrodes (1) |
| 3.2.5. | Substrates for alkaline electrolyzer electrodes (2) |
| 3.2.6. | Key considerations in electrode design for alkaline electrolyzers |
| 3.2.7. | Cathode: Hydrogen evolution reaction (HER) |
| 3.2.8. | Alkaline HER volcano & cathode catalysts |
| 3.2.9. | Common AEL cathode catalysts used commercially (1) |
| 3.2.10. | Common AEL cathode catalysts used commercially (2) |
| 3.2.11. | Emerging AEL cathode catalyst formulations (1) |
| 3.2.12. | Emerging AEL cathode catalyst formulations (2) |
| 3.2.13. | Comparison of hydrogen evolution catalysts |
| 3.2.14. | Approaches to improved HER catalyst design |
| 3.2.15. | Anode: oxygen evolution reaction (OER) |
| 3.2.16. | Oxygen evolution catalysts - finding the sweet spot |
| 3.2.17. | Common AEL anode catalysts used commercially |
| 3.2.18. | Platinum group metals are used in some advanced alkaline stacks |
| 3.2.19. | Case study - Asahi Kasei's hydrogen evolution catalyst |
| 3.2.20. | Emerging AEL anode catalyst formulations |
| 3.2.21. | Comparison of oxygen evolution catalysts |
| 3.2.22. | Approaches to improved OER catalyst design |
| 3.2.23. | Catalyst coating techniques for electrodes (1) |
| 3.2.24. | Catalyst coating techniques for electrodes (2) |
| 3.2.25. | Electrode activation processes |
| 3.2.26. | Electrode manufacturing case study: Nel Hydrogen (1) |
| 3.2.27. | Electrode manufacturing case study: Nel Hydrogen (2) |
| 3.2.28. | De Nora - leading electrode manufacturer for alkaline electrolyzers (1) |
| 3.2.29. | De Nora - leading electrode manufacturer for alkaline electrolyzers (2) |
| 3.2.30. | Veco - high surface area electrodes |
| 3.2.31. | Stargate Hydrogen - ceramic-based electrodes |
| 3.2.32. | McPhy & Stargate Hydrogen partnership for ceramic electrodes |
| 3.2.33. | Bifunctional catalysts for alkaline & seawater electrolysis |
| 3.2.34. | Catrodes - bifunctional catalysts |
| 3.2.35. | Jolt Solutions' new manufacturing process for AEL electrodes |
| 3.2.36. | ENDURE project - porous transport electrodes (PTEs) for AEL (1) |
| 3.2.37. | ENDURE project - porous transport electrodes (PTEs) for AEL (2) |
| 3.2.38. | ENDURE project - porous transport electrodes (PTEs) for AEL (3) |
| 3.3. | AEL separators (diaphragms) |
| 3.3.1. | AEL - porous diaphragm summary |
| 3.3.2. | Alkaline electrolyzer diaphragms & separators |
| 3.3.3. | Comparison of common diaphragms |
| 3.3.4. | Materials used for construction of commercial diaphragms |
| 3.3.5. | Agfa's Zirfon separator - incumbent material for AEL diaphragms |
| 3.3.6. | Agfa's Zirfon separator - product lines & properties |
| 3.3.7. | Agfa's Zirfon separator - commercial advancement |
| 3.3.8. | Alternatives to Zirfon separators |
| 3.3.9. | Other alkaline electrolyzer separator suppliers (1) |
| 3.3.10. | Other alkaline electrolyzer separator suppliers (2) |
| 3.3.11. | Potential material suppliers for diaphragm manufacturing |
| 3.3.12. | Electrolyzer OEMs using their own diaphragm materials |
| 3.3.13. | Novamem's Slash porous alkaline diaphragm (1) |
| 3.3.14. | Novamem's Slash porous alkaline diaphragm (2) |
| 3.3.15. | Catalyst coated diaphragms for alkaline electrolyzers (1) |
| 3.3.16. | Catalyst coated diaphragms for alkaline electrolyzers (2) |
| 3.3.17. | Future directions for AEL separators |
| 3.3.18. | Improving porous diaphragms (1/2) |
| 3.3.19. | Improving porous diaphragms (2/2) |
| 3.3.20. | Ion-solvating membranes (ISMs) |
| 3.3.21. | Polybenzimidazole (PBI) ion-solvating membranes |
| 3.4. | AEL bipolar plates & porous transport layers (PTLs) |
| 3.4.1. | AEL - bipolar plate (BPP) summary |
| 3.4.2. | Other bipolar plate designs |
| 3.4.3. | AEL - porous transport layer (PTL) summary |
| 3.4.4. | Porous transport layers (PTLs) |
| 3.4.5. | Evolution of alkaline electrolyzer cell electrodes & porous transport layers |
| 3.5. | AEL gaskets & stack assembly components |
| 3.5.1. | Gaskets for AEL |
| 3.5.2. | AEL gaskets |
| 3.5.3. | AEL gasket materials (1) |
| 3.5.4. | AEL gasket materials (2) |
| 3.5.5. | AEL cell frame |
| 3.5.6. | AEL end plates & stack assembly (1) |
| 3.5.7. | AEL end plates & stack assembly (2) |
| 3.5.8. | Röchling Group - PEEK end plates & bolts |
| 4. | PROTON EXCHANGE MEMBRANE ELECTROLYZER (PEMEL) MATERIALS & COMPONENTS |
| 4.1. | Overview of the PEM electrolyzer component supply chain |
| 4.1.1. | Proton exchange membrane fuel cell - overview |
| 4.1.2. | PEM fuel cell component summary |
| 4.1.3. | Proton exchange membrane electrolyzer (PEMEL) - overview |
| 4.1.4. | PEM electrolyzer component summary |
| 4.1.5. | PEMEL materials & components summary |
| 4.1.6. | PEM electrolyzer vs PEM fuel cell components |
| 4.1.7. | PEMEL materials & components supplier summary (1/2) |
| 4.1.8. | PEMEL materials & components supplier summary (2/2) |
| 4.1.9. | PEMEL stack suppliers |
| 4.1.10. | PEMEL component supply chain (1/2) |
| 4.1.11. | PEMEL component supply chain (2/2) |
| 4.1.12. | PEMEL membrane suppliers |
| 4.1.13. | PEMEL gasket / seal suppliers |
| 4.1.14. | PEMEL anode titanium PTLs |
| 4.1.15. | PEMEL cathode carbon GDLs |
| 4.1.16. | PEMEL bipolar plate manufacturers |
| 4.1.17. | PEMEL catalyst suppliers |
| 4.1.18. | PEMEL catalyst coated membrane (CCM) suppliers |
| 4.1.19. | PEMEL coating equipment / services suppliers |
| 4.2. | PEMEL catalysts & electrodes |
| 4.2.1. | PEMEL - catalysts (anode & cathode) summary |
| 4.2.2. | Cathode: Hydrogen evolution reaction (HER) |
| 4.2.3. | Acidic HER volcano & cathode catalysts |
| 4.2.4. | Commercial platinum on carbon (Pt/C) catalysts |
| 4.2.5. | Influence of carbon black support on Pt/C |
| 4.2.6. | Nippon Steel Chemical & Material - mesoporous carbon support for Pt/C catalysts |
| 4.2.7. | Comparison of HER electrocatalysts |
| 4.2.8. | Future directions for HER catalysts |
| 4.2.9. | Anode: Oxygen evolution reaction (OER) |
| 4.2.10. | Acidic OER volcano & cathode catalysts |
| 4.2.11. | Commercial iridium-based catalysts |
| 4.2.12. | Ir-Ru mixed metal oxide (MMO) catalysts |
| 4.2.13. | Ames Goldsmith Ceimig case study |
| 4.2.14. | Ames Goldsmith Ceimig - new Ir-Pt OER catalyst |
| 4.2.15. | Heraeus - new supported IrOx OER catalyst |
| 4.2.16. | Smoltek - new nanostructured catalysts |
| 4.2.17. | Comparison of OER electrocatalysts |
| 4.2.18. | Future directions for OER catalysts |
| 4.2.19. | Catalyst degradation mechanisms |
| 4.2.20. | Catalyst degradation examples |
| 4.2.21. | Electrocatalyst production overview |
| 4.2.22. | Example Pt/C production process |
| 4.2.23. | Recent trends from precious metal catalyst manufacturers |
| 4.2.24. | 3M's nanostructure iridium catalyst (1) |
| 4.2.25. | 3M's nanostructure iridium catalyst (2) |
| 4.2.26. | Calicat - using AI to develop PGM-free PEM electrolyzer catalysts |
| 4.3. | Proton exchange membranes (PEMs) |
| 4.3.1. | PEMEL - proton exchange membrane summary |
| 4.3.2. | Proton exchange membranes - brief history, functions & materials |
| 4.3.3. | PEM fuel cell vs electrolyzer membranes |
| 4.3.4. | Key parameters defining PFSA ionomer structure & properties |
| 4.3.5. | Overview of factors causing PEM membrane degradation |
| 4.3.6. | Historical perspective on membrane manufacturers & key properties |
| 4.3.7. | Nafion - the market leading membrane |
| 4.3.8. | Chemours' Nafion properties & grades |
| 4.3.9. | Pros & cons of Nafion & PFSA membranes |
| 4.3.10. | Proton exchange membrane market landscape |
| 4.3.11. | Leading modern PFSA membranes - key players & properties |
| 4.3.12. | Comparison of PFSA membrane properties |
| 4.3.13. | Ion exchange membrane material benchmarking - PEM fuel cells |
| 4.3.14. | Ion exchange membrane material benchmarking - PEM water electrolyzers |
| 4.3.15. | Example supply chain for proton exchange membranes - Gore |
| 4.3.16. | Future directions for MEAs: H2/O2 recombination layer |
| 4.3.17. | Chemours gas recombination catalyst additive research |
| 4.3.18. | Reducing PEMEL membrane thickness without impacting safety (1) |
| 4.3.19. | Minimizing LCOH with proton exchange membranes (PEM) |
| 4.3.20. | High-temperature proton exchange membranes |
| 4.3.21. | Innovations in PEMFC membranes may influence PEMEL (1) |
| 4.3.22. | Innovations in PEMFC membranes may influence PEMEL (2) |
| 4.3.23. | Ongoing concerns with PFAS |
| 4.3.24. | Hydrocarbons as proton exchange membranes |
| 4.3.25. | Alternative PEM materials: Hydrocarbon IEMs |
| 4.3.26. | Toray's hydrocarbon proton exchange membrane |
| 4.3.27. | Assessment of hydrocarbon membranes |
| 4.3.28. | Benchmarking of Ionomr membrane against incumbent PFAS membrane |
| 4.4. | Proton exchange membrane innovations & manufacturing |
| 4.4.1. | Fluoropolymers in the polymer pyramid |
| 4.4.2. | PFSA ionomer design |
| 4.4.3. | PFSA membrane extrusion casting process |
| 4.4.4. | PFSA membrane solution casting process |
| 4.4.5. | Special release membrane for PFSA solution casting process |
| 4.4.6. | PFSA membrane dispersion casting process |
| 4.4.7. | Melt-blowing PEM manufacturing process - NRC Canada |
| 4.4.8. | Improvements to PFSA membranes |
| 4.4.9. | Trade-offs in optimizing membrane performance |
| 4.4.10. | Improving dimensional and mechanical stability using simultaneous stretching |
| 4.4.11. | Reinforced PFAS membranes: Multilayer vs woven membranes |
| 4.4.12. | Chemours reinforced Nafion membranes |
| 4.4.13. | Gore reinforced SELECT membranes |
| 4.4.14. | Reinforcing ion exchange membranes using multilayer co-extrusion |
| 4.4.15. | Material companies are venturing into membrane reinforcement |
| 4.4.16. | Innovation areas for reinforced multilayer IEMs |
| 4.4.17. | PFSA composite materials |
| 4.5. | Catalyst coated membranes (CCMs) for PEMELs |
| 4.5.1. | PEMEL - CCM / MEA summary |
| 4.5.2. | PEMEL vs PEMFC membrane electrode assembly |
| 4.5.3. | Typical catalyst coated membrane (CCM) |
| 4.5.4. | CCM production technologies |
| 4.5.5. | Comparison of coating processes |
| 4.5.6. | Roll-to-roll CCM production processes (1/2) |
| 4.5.7. | Roll-to-roll CCM production processes (2/2) |
| 4.5.8. | RWTH Aachen & Laufenberg's research into CCM production |
| 4.5.9. | Fraunhofer ISE MEA research (1/2) |
| 4.5.10. | Fraunhofer ISE MEA research (2/2) |
| 4.5.11. | Catalyst ink formulation - key considerations |
| 4.5.12. | Future directions for MEAs: Understanding degradation mechanisms |
| 4.5.13. | Future directions for MEAs: Iridium deposition on GDL/PTL using SparkNano's sALD |
| 4.5.14. | Future directions for MEAs: Iridium deposition on GDL/PTL using Toshiba's vacuum sputtering technology |
| 4.5.15. | Future directions for MEAs: Direct membrane deposition (DMD) |
| 4.5.16. | Future directions for MEAs: H2/O2 recombination layer |
| 4.6. | PEMEL gas diffusion layers (GDLs) & porous transport layers (PTLs) |
| 4.6.1. | PEMEL - porous transport layer (PTL) & gas diffusion layer (GDL) summary |
| 4.6.2. | PTL/GDL characteristics & materials |
| 4.6.3. | Typical GDL structure |
| 4.6.4. | Cathode GDL: Hydrophobic treatment |
| 4.6.5. | Cathode GDL production process |
| 4.6.6. | Cellulosic fiber GDL: No MPL required |
| 4.6.7. | GDL innovation trends |
| 4.6.8. | AvCarb - advancements in GDL designs for fuel cells |
| 4.6.9. | GDL supply chain for FCEV stacks |
| 4.6.10. | Key GDL suppliers |
| 4.6.11. | Titanium porous transport layer (PTL) |
| 4.6.12. | Anode PTL: Sintered porous titanium |
| 4.6.13. | Interactions between PTL & catalyst layer |
| 4.6.14. | Bekaert - sintered titanium PTL |
| 4.6.15. | Caplinq - example Ti PTL production process |
| 4.6.16. | Shinsung C&T - electronics component manufacturer venturing into electrolyzer materials |
| 4.6.17. | Sintered powder Ti felt production |
| 4.6.18. | Future directions for anode Ti PTL |
| 4.7. | PEMEL bipolar plates (BPPs) & coatings |
| 4.7.1. | PEMEL - bipolar plate (BPP) & coating summary |
| 4.7.2. | Bipolar plate flow fields |
| 4.7.3. | Comparison of flow fields |
| 4.7.4. | Future directions for bipolar plate flow fields |
| 4.7.5. | Bipolar plate materials overview |
| 4.7.6. | PEMEL cannot use graphite BPPs |
| 4.7.7. | Bipolar plate manufacturing methods focus on metal plates |
| 4.7.8. | Graebener - bipolar plate production technology |
| 4.7.9. | Consortium approach for production of BPPs |
| 4.7.10. | Feintool & SITEC bipolar plate manufacturing process |
| 4.7.11. | Commercial bipolar plate: Platinum-coated titanium |
| 4.7.12. | HEF Groupe: New PVD coating technologies |
| 4.7.13. | Gold cathode & platinum anode BPP coating |
| 4.7.14. | Ionbond - new coating technology |
| 4.7.15. | Ti-coated stainless steel BPPs |
| 4.7.16. | Sydrogen - new BPP coating technology |
| 4.7.17. | James Cropper's BPP & PTL coating technology |
| 4.7.18. | Future coatings for metal bipolar plates |
| 4.7.19. | Carbon composite bipolar plate materials |
| 4.7.20. | Conventional metallic bipolar plate process |
| 4.7.21. | Advanced photochemical etching processes |
| 4.7.22. | Comparison of production methods |
| 4.8. | PEMEL gaskets & stack assembly components |
| 4.8.1. | Gaskets for PEMEL |
| 4.8.2. | PEMEL gasket functions & requirements |
| 4.8.3. | Gasket design considerations |
| 4.8.4. | Gasket material selection (1/2) |
| 4.8.5. | Gasket material selection (2/2) |
| 4.8.6. | O-ring & injection molded gaskets |
| 4.8.7. | WEVO-CHEMIE - liquid gaskets for electrolyzers |
| 4.8.8. | PEMEL cell frames |
| 4.8.9. | PEMEL end plates & stack assembly (1/2) |
| 4.8.10. | Stack assembly example - Plug Power |
| 4.8.11. | Syensqo - PPS endplates for PEM fuel cells |
| 5. | ANION EXCHANGE MEMBRANE ELECTROLYZER (AEMEL) MATERIALS & COMPONENTS |
| 5.1. | Overview of AEM electrolyzer materials |
| 5.1.1. | Anion exchange membrane electrolyzer (AEMEL) plant - operating principles |
| 5.1.2. | The case for AEMEL development |
| 5.1.3. | AEMEL's similarities to AEL & PEMEL |
| 5.1.4. | Why AEM electrolyzer development is progressing quickly |
| 5.1.5. | AEMEL materials & components summary |
| 5.1.6. | Enapter - the leading AEMEL company |
| 5.1.7. | AEMEL stack & anion exchange membrane suppliers |
| 5.2. | Anion exchange membranes (AEMs) |
| 5.2.1. | AEMEL - anion exchange membrane summary |
| 5.2.2. | Anion exchange membranes (AEMs) in AEMELs |
| 5.2.3. | Anion exchange membrane (AEM) materials |
| 5.2.4. | AEM material challenges & prospects |
| 5.2.5. | Comparison of commercial AEM materials |
| 5.2.6. | High-performance AEMELs require engineering beyond just membranes |
| 5.2.7. | Commercial hydrocarbon AEM material examples (I) |
| 5.2.8. | Commercial hydrocarbon AEM material examples (II) |
| 5.2.9. | Versogen's anion exchange membrane |
| 5.2.10. | Orion polymer (1) |
| 5.2.11. | Orion polymer (2) |
| 5.2.12. | Enapter - the leading AEMEL company |
| 5.2.13. | AEMEL stack & anion exchange membrane suppliers |
| 5.2.14. | Ion exchange membrane material benchmarking - AEM water electrolyzers |
| 5.2.15. | Gen-Hy's vertical integration for AEM electrolyzers |
| 5.3. | AEMEL electrodes, bipolar plates, transport layers & other components |
| 5.3.1. | AEMEL - electrodes / catalysts and CCM / MEA summary |
| 5.3.2. | AEMEL catalysts overview |
| 5.3.3. | AEMEL catalysts summary |
| 5.3.4. | AEMEL membrane electrode assembly (MEA) |
| 5.3.5. | Commercial AEMEL MEA design |
| 5.3.6. | TNO and partners aim for AEM electrolyzer component standardization |
| 5.3.7. | NovaMea - new AEMEL membranes, ionomers and catalysts (1) |
| 5.3.8. | NovaMea - new AEMEL membranes, ionomers and catalysts (2) |
| 5.3.9. | AEMEL - bipolar plates, porous transport layers, gas diffusion layers |
| 5.3.10. | Gaskets for AEMEL |
| 6. | SOLID OXIDE ELECTROLYZERS (SOEC) MATERIALS & COMPONENTS |
| 6.1. | Overview of SOEC component supply chain |
| 6.1.1. | Solid oxide electrolyzer (SOEC) |
| 6.1.2. | US DOE technical targets for SOEC |
| 6.1.3. | SOEC materials & components summary |
| 6.1.4. | SOEC materials & components summary |
| 6.1.5. | SOEC materials & components supplier summary |
| 6.1.6. | SOEC & SOFC stack suppliers |
| 6.1.7. | SOEC component supply chain |
| 6.1.8. | SOEC electrolyte & electrode material suppliers |
| 6.1.9. | SOEC sealing & insulating material suppliers |
| 6.1.10. | SOEC interconnect metals & coatings material suppliers |
| 6.2. | SOEC electrolytes |
| 6.2.1. | SOEC - electrode electrolyte assembly (EEA) (1) |
| 6.2.2. | SOEC - electrode electrolyte assembly (EEA) (2) |
| 6.2.3. | SOEC electrolyte functions & requirements |
| 6.2.4. | Yttria-stabilized zirconia (YSZ) electrolyte |
| 6.2.5. | YSZ electrolyte technical & commercial considerations |
| 6.2.6. | Alternative electrolyte materials |
| 6.2.7. | Impact of LT-SOFC electrolyte development |
| 6.2.8. | Comparison of electrolyte materials |
| 6.2.9. | Advanced Ionics' lower temperature electrolyte and SOEC |
| 6.3. | SOEC electrodes |
| 6.3.1. | Cathode: Hydrogen evolution reaction (HER) |
| 6.3.2. | Ni cermet - the conventional material |
| 6.3.3. | Improving cathode materials |
| 6.3.4. | Anode: Oxygen evolution reaction (OER) |
| 6.3.5. | LSM-YSZ - the conventional material |
| 6.3.6. | LSC & LSCF - new state-of-the-art materials (1/2) |
| 6.3.7. | LSC & LSCF - new state-of-the-art materials (2/2) |
| 6.3.8. | Alternative anode materials & innovations |
| 6.3.9. | SOEC component degradation challenges |
| 6.3.10. | Degradation mechanisms & mitigation strategies for SOECs & SOFCs |
| 6.4. | SOEC interconnects, coatings & contact layers |
| 6.4.1. | SOEC - interconnects, coatings & contact layers summary |
| 6.4.2. | SOEC interconnect functions & requirements |
| 6.4.3. | Ceramic interconnects |
| 6.4.4. | Improving ceramic interconnects |
| 6.4.5. | Metallic interconnects |
| 6.4.6. | Protective coatings for metallic interconnects |
| 6.4.7. | fuelcellmaterials' coating for metallic interconnects |
| 6.4.8. | Contact layers for metallic interconnects |
| 6.4.9. | Alleima's pre-coated stainless steel |
| 6.4.10. | Contact layer commercial example |
| 6.5. | SOEC sealants & insulating materials |
| 6.5.1. | SOEC - gaskets & sealants summary |
| 6.5.2. | SOEC sealant functions & requirements |
| 6.5.3. | Compressive sealants |
| 6.5.4. | Flexitallic - Thermiculite sealing technology (1) |
| 6.5.5. | Flexitallic - Thermiculite sealing technology (2) |
| 6.5.6. | Glass-ceramic sealants |
| 6.5.7. | Mo-Sci - viscous compliant sealants |
| 6.5.8. | SOEC insulation functions & requirements |
| 6.5.9. | SOEC insulating materials |
| 6.6. | SOEC cell manufacturing & stack assembly |
| 6.6.1. | Tubular vs planar SOEC & SOFC cells |
| 6.6.2. | Solid oxide cell configurations |
| 6.6.3. | Ceramic cell manufacturing process (1) |
| 6.6.4. | Ceramic cell manufacturing process (2) |
| 6.6.5. | Manufacturing process variations & new processes |
| 6.6.6. | Idaho National Lab - advanced sintering technology for solid oxide cells |
| 6.6.7. | Metal-supported cell features & manufacturing |
| 6.6.8. | Ceres Power - commercial SOFC example |
| 6.6.9. | Metallic component manufacturing, component integration & assembly |
| 6.6.10. | Elcogen - commercial SOEC cell example |
| 6.6.11. | Topsoe's SOEC cell development & outlook |
| 6.6.12. | OxEon Energy - SOEC cell & stack design |
| 7. | ELECTROLYZER MANUFACTURING & MATERIAL MARKET TRENDS |
| 7.1. | Electrolyzer manufacturing innovations |
| 7.1.1. | Manufacturing scale-up as a key lever for electrolyzer cost reductions |
| 7.1.2. | Accelera by Cummins: Strategies for LCOH reduction |
| 7.1.3. | thyssenkrupp nucera: Perspectives from a large electrolyzer OEM |
| 7.1.4. | Electrolyzer manufacturing challenges overview |
| 7.1.5. | Simultaneous engineering in electrolyzer design |
| 7.1.6. | thyssenkrupp - scaling up electrolyzer & fuel cell manufacturing |
| 7.1.7. | Hitachi High-Tech - in-line inspection for fuel cell & electrolyzers |
| 7.1.8. | AVL - optimization & testing for fuel cells & electrolyzers |
| 7.2. | Alternatives to PFAS in ion exchange membranes |
| 7.2.1. | PFAS in ion exchange membranes (IEMs) |
| 7.2.2. | PFAS in IEMs: Outlook by application |
| 7.2.3. | Chemours' focus on responsible manufacturing of Nafion |
| 7.2.4. | Key parameters required to replace PFAS membranes |
| 7.2.5. | Emerging alternative membranes |
| 7.2.6. | Hydrocarbon membranes are leading competitors to PFAS-containing membranes |
| 7.2.7. | Alternative polymer materials for ion exchange membranes |
| 7.2.8. | Boron-containing hydrocarbon membranes |
| 7.2.9. | Other non-PBI containing ion solvating membranes |
| 7.2.10. | Glass-filled cross-linked PEEK for improved membrane stiffness |
| 7.2.11. | Bio-based PFSA-free membranes based on cellulose |
| 7.2.12. | Inorganic and inorganic-organic hybrid ion exchange membranes |
| 7.2.13. | Inorganic membranes: Membrion |
| 7.2.14. | Metal-organic frameworks (MOFs) - overview |
| 7.2.15. | MOF applications in ion exchange membranes |
| 7.2.16. | MOF-based ion exchange membranes are not ready for commercialization |
| 7.2.17. | Commercial maturity of PFAS alternatives in ion exchange membranes |
| 7.3. | PFAS in seals & gaskets |
| 7.3.1. | PFAS in seals and gaskets for high-tech applications |
| 7.3.2. | Common materials utilized for sealing applications |
| 7.3.3. | Fluoropolymers in the polymer pyramid |
| 7.3.4. | Dominance of PTFE & fluoroelastomers in sealing applications |
| 7.3.5. | Sealing for the hydrogen value chain |
| 7.3.6. | Sealing for the hydrogen value chain |
| 7.3.7. | Sealing for the hydrogen value chain |
| 7.3.8. | Sealing for the hydrogen value chain |
| 7.3.9. | Electrolyzer gasket materials |
| 7.3.10. | Electrolyzer gasket materials |
| 7.3.11. | Gasket material selection |
| 7.3.12. | Gasket material selection |
| 7.3.13. | Application example 2 - hydrogen value chain |
| 7.3.14. | European Sealing Association (ESA) opinions on PFAS bans |
| 7.3.15. | Seals and gaskets supply chain overview |
| 7.3.16. | Seals and gaskets supply chain: Selected companies |
| 7.3.17. | Materials suppliers for seals and gaskets: Non-PFAS and PFAS materials |
| 7.3.18. | Materials suppliers for seals and gaskets (1) |
| 7.3.19. | Materials suppliers for seals and gaskets (2) |
| 7.3.20. | Potential PFAS-free alternatives for sealing applications in the hydrogen sector |
| 7.3.21. | Potential for PFAS-free alternatives for sealing applications |
| 7.3.22. | Trends towards liquid sealants supports non-PFAS sealing materials |
| 7.3.23. | Cure mechanisms for liquid sealants |
| 7.3.24. | Key materials and players for liquid sealants |
| 7.3.25. | DuPont - PI for hydrogen sealing |
| 7.3.26. | WEVO-CHEMIE - liquid sealants |
| 7.3.27. | Syensqo's alternatives to fluoropolymers |
| 7.3.28. | Omniseal Solutions - variety of PFAS alternatives |
| 7.3.29. | Freudenberg Sealing Technologies - view on regulations |
| 7.3.30. | Freudenberg Sealing Technologies - new PU material |
| 7.3.31. | SGL Carbon - graphite sealants |
| 7.3.32. | Metallic gaskets as PFAS alternatives |
| 7.3.33. | Summary and conclusions - PFAS alternatives for seals and gaskets |
| 7.4. | Platinum group metal (PGM) supply chains considerations |
| 7.4.1. | Critical minerals for the hydrogen economy |
| 7.4.2. | Global critical mineral supply chains |
| 7.4.3. | Clean energy applications competing for raw materials |
| 7.4.4. | Green hydrogen's influence on minerals |
| 7.4.5. | Platinum & iridium supply chain considerations |
| 7.4.6. | Historical iridium price volatility |
| 7.4.7. | Historical iridium supply and demand |
| 7.4.8. | Will iridium supply limit the growth of PEMEL? |
| 7.4.9. | Precious metal supply risk |
| 7.4.10. | Heraeus' views on the iridium market |
| 7.4.11. | Heraeus' focus on ruthenium catalysts |
| 7.4.12. | Heraeus - challenges in transitioning to new PEMEL catalysts |
| 7.4.13. | Importance of technological advancements & PGM recycling |
| 7.4.14. | Heraeus - PGM recycling from electrolyzers & fuel cells |
| 7.4.15. | Fraunhofer IWKS - recovery of materials from end-of-life fuel cells |
| 7.5. | Considerations for hydrogen embrittlement in metallic components |
| 7.5.1. | Hydrogen embrittlement & compatible metal alloys |
| 7.5.2. | Influence of nickel in austenitic stainless steels for H2 applications |
| 7.5.3. | Influence of Ti in austenitic stainless steels for H2 applications |
| 8. | MARKET FORECASTS FOR ELECTROLYZER COMPONENTS |
| 8.1.1. | Forecasting methodology & assumptions (1) |
| 8.1.2. | Forecasting methodology & assumptions (2) |
| 8.1.3. | Annual electrolyzer demand by technology (GW) |
| 8.1.4. | Electrolyzer stack cost forecasts by technology (US$/kW) |
| 8.1.5. | Electrolyzer stack cost forecasts by component (%) |
| 8.1.6. | Annual electrolyzer components market by technology (US$M) |
| 8.1.7. | AEL - components forecast by area (1000s m2) |
| 8.1.8. | AEL - components forecast by weight (kilotonnes) |
| 8.1.9. | AEL - components market forecast (US$ millions) |
| 8.1.10. | PEMEL - components forecast by area (1000s m2) |
| 8.1.11. | PEMEL - precious metals forecast by weight (tonnes) |
| 8.1.12. | PEMEL - components forecast by weight (kilotonnes) |
| 8.1.13. | PEMEL - components market forecast (US$ millions) |
| 8.1.14. | SOEC - metallic components forecast by weight (tonnes) |
| 8.1.15. | SOEC - ceramic components forecast by weight (tonnes) |
| 8.1.16. | SOEC - components forecast by area (1000s m2) |
| 8.1.17. | SOEC - components market forecast (US$ millions) |
| 8.1.18. | AEMEL - components forecast by area (1000s m2) |
| 8.1.19. | AEMEL - components forecast by weight (tonnes) |
| 8.1.20. | AEMEL - components market forecast (US$M) |
| 9. | COMPANY PROFILES |
| 9.1. | 1s1 Energy |
| 9.2. | Agfa-Gevaert NV: Alkaline Electrolyzer Separator |
| 9.3. | Alleima: Fuel Cell BPP & Interconnect Materials |
| 9.4. | Ames Goldsmith Ceimig: PEMEL/FC Electrocatalysts |
| 9.5. | Asahi Kasei: Aqualyzer (Green Hydrogen) |
| 9.6. | AvCarb |
| 9.7. | CellMo |
| 9.8. | Ceres Power |
| 9.9. | De Nora: Alkaline Electrolyzer Electrodes |
| 9.10. | Evonik |
| 9.11. | Fraunhofer IKTS: SOEC/SOFC Technology |
| 9.12. | Fumatech |
| 9.13. | Heraeus: Catalysts for the Hydrogen Economy |
| 9.14. | Hyproof Tech. |
| 9.15. | IHI Ionbond: Coatings for Bipolar Plates |
| 9.16. | INEOS Electrochemical Solutions |
| 9.17. | Ionomr Innovations |
| 9.18. | Ionomr Innovations |
| 9.19. | Jolt Solutions |
| 9.20. | KnitMesh Technologies: Electrolyzer Electrodes & PTL/GDLs |
| 9.21. | Nel ASA: AWE Electrodes & Manufacturing Facilities |
| 9.22. | Nippon Steel Chemical & Material: Mesoporous Carbon Material |
| 9.23. | Orion Polymer |
| 9.24. | Shinsung C&T: EV Fire Protection & Electrolyzer Materials |
| 9.25. | Stargate Hydrogen |
| 9.26. | Teijin: Gas Diffusion Layer (GDL) for PEM Fuel Cells |
| 9.27. | thyssenkrupp nucera |
| 9.28. | Versogen |
| 9.29. | WEVO-CHEMIE: Hydrogen & RFB Applications |
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IDTechEx forecasts the water electrolyzer component market to reach US$10.1 billion by 2036
Report Statistics
| Slides | 572 |
|---|---|
| Companies | 29 |
| Forecasts to | 2036 |
| Published | Jun 2025 |
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