Netherlands – Breakthrough brings $1/kg cost green hydrogen closer

Dutch firm VSPARTICLE achieved a breakthrough in iridium barrier technology for proton exchange membrane (PEM) electrolyzers. Their layer technology has demonstrated a tenfold improvement in iridium utilization, paving the way for cost-competitive green hydrogen production. Iridium is a key yet scarce material used for hydrogen production.

This breakthrough, achieved with hydrogen fuel cell maker Plug Power Inc. and the Center for Clean Hydrogen at the University of Delaware, surpasses the US Department of Energy’s 2026 targets for iridium utilization and performance. It paves the way for green hydrogen (generated from renewable electricity) to reach cost parity with standard hydrogen at $1/kg.

The core of VSParticle’s recent achievement lies in its innovative use of iridium in PEM electrolyzers. PEM electrolyzers, crucial for green hydrogen production, rely on iridium, an extremely rare platinum group metal. The annual global production of iridium is limited to 7-8 tonnes, making it a major bottleneck for scaling up electrolyzer production. Traditional catalyst coating methods require 1 to 2 mg/cm² of iridium, further exacerbating the scarcity issue.

VSPARTICLE’s new technology significantly reduces iridium usage by up to 90%, lowering the loading from 1.0 mg/cm² to as little as 0.1 mg/cm² while maintaining high performance. This is achieved through a technology that creates a highly uniform, nanoporous structure, thereby maximizing the electrochemical surface area and simplifying the manufacturing process.

VSPARTICLE is scaling its in-house coating capacity to support pilot and early commercial projects with multiple top-tier PEM electrolyzer manufacturers. Several partners have scheduled integration and commercial-scale testing programs to begin in 2026.