New Energies, new possibilities

Danish technology company Topsoe is targeting 5 to 16% revenue growth this year with its solid oxide electrolyser cell (SOEC) factory set to open in Herning in the first half of 2025.

While gross profit was fractionally up in 2024 (DKK3.58bn ($498.1m), compared with DKK3.56bn ($495.3m) in 2023), revenues fell from DKK9.41bn ($1.309bn) to DKK8.37bn ($1.2bn), mainly down to catalyst business sales, and cashflow from operating activities dropped to DKK966m ($134.3m).

Around a quarter of revenue (23%) came from businesses related to technologies and solutions that enable the production of low-carbon, renewable fuels and e-fuels. Energy consumption decreased from 359,172MWh to 338,335 MWh.

Roeland Baan, CEO of Topsoe, said 2024 was a “solid year” with its catalyst and technology businesses continuing to support customer projects worldwide. He said the company is well placed to support all types of fuel solutions to meet growing energy demand. In the second quarter, Topsoe raised €200m through a green hybrid bonds issue.

The opening of the Herning plant, which had been slightly delayed from its original 2024 target, aims to produce up to 500MW of solid oxide electrolyser cells (SOECs) annually, supporting the production of green hydrogen and its derivatives. The facility received €94 million in funding from the EU Emissions Trading System (ETS) Innovation Fund.

As the facility gears up for production, automation will play a critical role.

Peter Aggerholm, Production Manager, said, “This strategic move ensures efficiency and reduces reliance on manual processes, supported by thorough training and robust research and development backup. New York-headquartered First Ammonia finalised sales and service agreements with Topsoe for the fabrication of the first 100MW of SOEC modules last October. Topsoe will provide the systems from its new factory to the US-based project at the Port of Victoria in Texas.

The Danish company added that a final decision on the expansion to the US  “will depend on market conditions and developments”.

High-temperature SOEC technology produces 30% more green hydrogen based on the same input of renewable power compared with standard technology, Topsoe claims.

The European Commission is aiming to deploy 40 gigawatts of electrolysers by 2030.

Aluminum (Al) is a material considered susceptible to corrosion, but it could become key to core technology in producing clean hydrogen energy. A POSTECH research team succeeded in dramatically improving the performance of hydrogen production catalysts using this unstable metal.

The research is published in the journal ACS Catalysis.

Hydrogen is being spotlighted as a clean energy source that could replace fossil fuels. In particular, research on alkaline water electrolysis using alkaline solution as an electrolyte is being actively conducted, as it is cost-effective and suitable for mass production.

Water electrolysis requires a catalyst that accelerates two important reactions. One of them is the hydrogen evolution reaction (HER), which produces hydrogen gas (H2) by combining hydrogen ions (H+) and electrons. The other is the oxygen evolution reaction (OER), which produces oxygen gas (O2) as hydroxyl ions (OH-) lose electrons. Nickel-iron (Ni-Fe) is a catalyst mainly used in the oxygen production reaction; however, it has had difficulties in commercializing due to its lack of activity and durability.

The research team solved the problem using aluminum. Aluminum is generally known to be easily corroded in alkaline environments, but the research team overcame the problem by designing it to form a stable structure on the surface of an electrode. As a result, aluminum efficiently controlled the existing catalytic electron structure without corrosion, accelerating the oxygen production reaction.

Experiments conducted in an alkaline water electrolysis cell showed that the nickel-iron-aluminum (Ni-Fe-Al) catalyst improved performance by approximately 50% compared to existing catalysts. The research team confirmed that the aluminum catalyst maintained high current density even at low voltage. Additionally, it was proven to be applicable in a large-scale hydrogen production process, as it maintained excellent stability in long-term operation.

Professor Yong-Tae Kim, the leader of this research, said, "This research broke the stereotypes of existing catalyst designs. By using this innovative approach of utilizing aluminum, we were able to drastically improve the performance of catalysts used in a hydrogen production system. I expect this research will substantially advance the hydrogen economy age and become a new milestone in eco-friendly energy technology."

Aluminum's surprising stability in alkaline environments enhances hydrogen production

A breakthrough in renewable energy research has led to the development of a cost-effective and highly efficient iron-based catalyst for water oxidation.

This innovation mimics natural photosynthesis while overcoming the limitations of expensive metal catalysts. The newly developed polymerized iron complex, poly-Fe5-PCz, boasts exceptional stability and near-perfect Faradaic efficiency, making it a game-changer for hydrogen production. By leveraging abundant materials, the study paves the way for scalable, sustainable energy solutions that could transform clean energy storage and industrial hydrogen generation.

Harnessing Water Oxidation for Renewable Energy

Water oxidation is a key process in renewable energy, particularly for hydrogen production and artificial photosynthesis. By splitting water into oxygen and hydrogen, it offers a clean and sustainable energy source. However, replicating the efficiency and stability of natural photosynthesis in artificial catalysts — especially in water-based environments — remains a major challenge. While catalysts made from rare metals like ruthenium are highly effective, their high cost and limited supply make them impractical for large-scale applications.

To overcome this, a research team led by Professor Mio Kondo from the Institute of Science Tokyo (Science Tokyo), Japan, developed a more sustainable and affordable catalytic system using widely available metals. Their study, published today (March 5) in Nature Communications, presents a promising alternative for advancing clean energy technology.

Introducing the Pentanuclear Iron Catalyst

The study introduces a novel pentanuclear iron complex, Fe5-PCz(ClO₄)₃, which possesses a multinuclear-complex-based catalytically active site and precursor moieties for charge transfer sites. Kondo explains, “By electrochemically polymerizing this multinuclear iron complex, we create a polymer-based material that enhances electrocatalytic activity and long-term stability. This approach combines the benefits of natural systems with the flexibility of artificial catalysts, paving the way for sustainable energy solutions.”

Poly-Fe5-PCz is a promising and efficient catalyst for water oxidation, offering a viable solution for hydrogen production and energy storage. Credit: Science Tokyo

Synthesizing and Characterizing the Catalyst

The researchers synthesized the Fe5-PCz(ClO₄)₃ complex using organic reactions like bromination, nucleophilic substitution, Suzuki coupling reactions, and subsequent complexation reactions. The synthesized complex was characterized by mass spectrometry, elemental analysis, and single-crystal X-ray structural analysis.

The researchers then modified glassy carbon and indium tin oxide electrodes by polymerizing Fe5-PCz using cyclic voltammetry and controlled potential electrolysis to afford a polymer-based catalyst, poly-Fe5-PCz.

The charge transfer ability and electrocatalytic performance of poly-Fe5-PCz were evaluated through electrochemical impedance spectroscopy and oxygen evolution reaction (OER) experiments with oxygen production quantified by gas chromatography, respectively.

Outstanding Performance and Stability

The results were highly promising. Kondo explains, “Poly-Fe5-PCz achieved up to 99% Faradaic efficiency in aqueous media, meaning nearly all the applied current contributed to the OER. The system also exhibited superior robustness and a reaction rate under rigorous testing conditions compared to relevant systems.

Additionally, poly-Fe5-PCz demonstrated enhanced energy storage potential and improved electrode compatibility, making it suitable for a wide range of renewable energy applications.” Its high stability was further confirmed by long-term controlled potential experiments, a key advantage for hydrogen production and energy storage technologies.

Implications for Sustainable Energy

The study’s findings have significant implications for sustainable energy. The use of iron — an abundant, non-toxic metal — ensures the system is both eco-friendly and cost-effective, offering a viable alternative to precious metal-based catalysts. Its stability under operational conditions addresses a major challenge in artificial catalytic systems, where long-term catalyst degradation often limits performance. Moreover, the system’s performance in aqueous environments makes it suitable for applications in water splitting.

Toward Scalable Hydrogen Production

“Optimizing poly-Fe5-PCz synthesis and scalability could further enhance its performance, paving the way for industrial-scale hydrogen production and energy storage. Our study opens new possibilities for integrating the system into broader energy technologies, paving the way to a more sustainable future,” concludes Kondo.

Reference: “Iron-complex-based catalytic system for high-performance water oxidation in aqueous media” by Takumi Matsuzaki, Kento Kosugi, Hikaru Iwami, Tetsuya Kambe, Hisao Kiuchi, Yoshihisa Harada, Daisuke Asakura, Taro Uematsu, Susumu Kuwabata, Yutaka Saga, Mio Kondo and Shigeyuki Masaoka, 5 March 2025, Nature Communications.

Source:  Fuel Cells Works