The PROMISERS project is developing sustainable alternatives to PFAS for use in proton exchange membrane fuel cells and electrolysers.
Green hydrogen is widely recognized by the European Commission as a key pillar of the EU’s clean energy transition. Fuel cell and electrolyzer technologies are expected to play a key role in achieving Europe’s emissions reduction targets, especially in sectors that are difficult to electrify. Among these technologies, solid polymer exchange membrane (PEM)-based fuel cells and electrolyzers stand out as the most mature and commercially viable solutions, currently dominating both in installed capacity and projected near-term growth.
However, all today’s PEM-based hydrogen technologies rely on per- and polyfluoroalkyl substances (PFAS), a group of thousands of synthetic chemicals that are widely used in the EU and around the world. Ultimately, these chemicals transform into persistent substances that can cause irreversible environmental exposure and accumulation in human tissues, causing adverse health effects.
Per- and polyfluoroalkyl substances (PFAS) in hydrogen technology: challenges and opportunities
PFAS are essential to the production of hydrogen-related products. This is typically the case for fuel cells and electrolysers that operate using PFAS-based membranes, most commonly PFSA (perfluoroalkylated sulfonic acids) such as NafionTM. This material is chemically and mechanically robust while exhibiting exceptional electrical conductivity due to its unique microstructure (microphase separation, ion-conducting channels). PFAS ionomers are also widely used in gas diffusion layers (GDLs), catalyst layers, microporous layers (MPLs), electrodes, etc. There are currently no commercially viable alternatives that exhibit the desirable physical and chemical properties of fluoropolymers, and a ban on PFAS without suitable alternatives could have a devastating impact on the industry’s investment worth €30 billion over 10 years (including only electrolyzers and fuel cells).
Promising alternative materials such as hydrocarbon-based polymers and cellulose have the potential to replace current PFAS-based materials. Specialty and mesoporous polymers based on aromatic hydrocarbons exhibit high thermal, chemical, and mechanical stability in acidic media due to their aromatic structure. Meanwhile, cellulose is the most abundant biopolymer, and its nanoscale forms, cellulose nanocrystals (CNCs) and cellulose nanofibrils (CNFs), are interesting materials for engineering key components of fuel cells and electrolyzers.
Promisers Project
The PROMISERS project was launched to address the lack of suitable PFAS replacements and develop new non-fluorinated materials to pave the way for fluorine-free PEM fuel cells and electrolysers.
The PROMISERS project aims to develop sustainable industrial processes for manufacturing PEM fuel cells and PEM electrolyser stacks using non-fluorinated components and materials. These include ionomers, membranes, membrane electrode assemblies (MEAs), MPLs, electrodes, and sealing elements. The ultimate goal of this project is to demonstrate the competitive performance, durability, and efficiency of these newly developed materials in fuel cells and electrolyser stacks.
Additionally, the project aims to examine circularity by design and the business potential of materials, scale-up strategies and production processes, both at process level and throughout the value chain. This is achieved by applying simulation approaches, safety design protocols, REACH compliance, and conducting life cycle assessment (LCA) and life cycle costing (LCC) evaluations. These initiatives ensure alignment of the European Green Deal priorities with the EU’s zero pollution goal. Throughout the project, materials and components progress from Technology Readiness Level (TRL) 1 to TRL 4, moving from fundamental research and proof of concept to laboratory-scale demonstration in relevant environments.
The project is funded by the European Commission’s Horizon Europe program with support from the Clean Hydrogen Partnership. PROMISERS was established by a consortium of European industry and research leaders and has a duration of three years and a budget of nearly €3 million. Consortium members include Syensqo (France, Italy), Fumatech (Germany), De Nora (Italy, Germany), RINA Consulting (Italy), Hysytech (Italy), TNO (Netherlands), IIT (Italy), Cellfion (Sweden), and Leitat (Spain) as coordinator.
From concept to validation: key developments in the PROMISERS project
This project follows two main approaches to developing non-fluorinated components for PEM fuel cells and electrolysers. The first approach is based on hydrocarbons and the second on nanocellulose. Each pathway begins with PFAS-free ionomer development and ink formulation, followed by MEA and single cell design, and culminates in the manufacturing and validation of PEM fuel cells and PEM electrolyzer stacks (Hysytech). The development of non-fluorinated components is supported by simulation studies and Operand Technologies (TNO, IIT).
The project was officially launched at the Leitat facility in January 2025 and is well underway. Syensqo has developed the first new hydrocarbon-based ionomer. This was distributed to consortium partners developing and characterizing components such as PEM membranes (Fumatech) and ink formulations (De Nora). Initial characterization results of the material are very promising. The consortium partners are currently focused on process optimization of the material to comply with REACH regulations and safety-oriented design protocols, and are looking into the possibility of scaling up the material to an industrial level and producing larger quantities by the end of the project (RINA).
In parallel, Cellfion and Leitat are advancing biobased approaches by optimizing cellulose nanocrystals (CNCs) and cellulose nanofibrils (CNFs) materials to improve membrane performance. Additionally, biobased nanofiber reinforced materials have been screened to improve the mechanical stability of PEM membranes. The first PEM membrane samples have been developed and are currently undergoing performance testing.
Successful implementation of the PROMISERS concept could result in approximately 500 tonnes of PFAS material reduction by 2030, based on fuel cell demand for 100,000 trucks and 1 million light vehicles. Regarding electrolyzers, a similar amount of 500 tonnes could be saved by 2030 for an electrolysis capacity of 40 GW.
Disclaimer
Project PROMISERS (grant agreement number 101192151). This project is supported by the Clean Hydrogen Partnership and its members. Funded by the European Union. However, the views and opinions expressed are those of the authors alone and do not necessarily reflect the views and opinions of the European Union or the Clean Hydrogen Bonding Business. Neither the European Union nor the licensing authorities can be held responsible for them.
This article will also be published in the quarterly magazine issue 24.
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