Electrochemical synthesis of hydrogen peroxide from water, air and renewable electric energy

Projektinformationen

Power2Hype

ID Finanzhilfevereinbarung: 101091934

DOI

10.3030/101091934

EK-Unterschriftsdatum 18 November 2022

Startdatum 1 Januar 2023

Enddatum 31 Dezember 2026

Finanziert unter

• Digital, Industry and Space

Gesamtkosten

€ 10 111 515,75

EU-Beitrag

€ 10 104 590,50

Koordiniert durch

FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV
Germany

Periodic Reporting for period 2 - Power2Hype (Electrochemical synthesis of hydrogen peroxide from water, air and renewable electric energy)

Berichtszeitraum: 2024-07-01 bis 2025-12-31

Zusammenfassung vom Kontext und den Gesamtzielen des Projekts

The Power2Hype project focuses on developing a sustainable, energy-efficient process for hydrogen peroxide (H2O2) production using renewable electricity, water, and air. Traditional H2O2 production methods are centralized, resource-intensive, and involve hazardous chemicals, presenting environmental and logistical challenges. Power2Hype aims to address these issues by creating a decentralized, flexible electrochemical production model that operates closer to end-users, generating H2O2 in final-required concentration, reducing both environmental impact and transportation costs.

The electrochemical process focuses on achieving high efficiency through the concept of paired electrolysis, where hydrogen peroxide is generated simultaneously at both the cathode and anode of the electrochemical cell. This dual-generation approach can potentially double the current efficiency, leading to greater yields with less energy consumption. The project’s objectives include the development of optimized cell components (catalyst materials, gas diffusion electrodes and membranes), the design and integration of a scalable electrochemical process, the construction of a custom-made stack-electrolyzer, and the piloting of the technology in real-world industrial environments. Additionally, Power2Hype will assess the economic and environmental sustainability of the new process, while formulating strategies for its commercial exploitation, ensuring the technology's long-term viability and impact.

The Power2Hype project aims to revolutionize H2O2 production by introducing a novel, electrochemical process that is both efficient and sustainable, addressing the global need for cleaner industrial practices. By integrating renewable energy sources and reducing reliance on traditional, resource-intensive methods, the project aligns with key political and strategic goals for carbon reduction and sustainability. The anticipated outcomes of Power2Hype have the potential to significantly impact the chemical industry, offering scalable solutions that contribute to the decarbonization of industrial processes and support the transition to a circular economy.

Arbeit, die ab Beginn des Projekts bis zum Ende des durch den Bericht erfassten Berichtszeitraums geleistet wurde, und die wichtigsten bis dahin erzielten Ergebnisse

The Power2Hype project has made significant progress in developing and demonstrating a novel electrochemical process for sustainable H2O2 production powered by renewable electricity. The approach enables decentralized, on-demand production of this key industrial chemical while reducing the environmental footprint compared to conventional processes.

Major advances have been achieved in large-scale cell component development. Carbon-based cathode catalysts were optimized, showing high selectivity and Faradaic efficiency at current densities up to 400 mA/cm². These catalysts were integrated into gas diffusion electrodes and upscaled to 200 cm². On the anodic side, boron-doped diamond electrodes are being further developed for paired electrolysis, demonstrating strong performance in both alkaline and acidic media. Membrane and ionomer innovation has also been central, including a novel hydrocarbon-based anion exchange membrane with promising conductivity. In addition, a porous solid polymer electrolyte produced via additive manufacturing has proven chemically resistant and proton-conductive, suitable for scale-up.

The project successfully scaled from lab cells to operational electrolysers now producing H2O2, confirming the technical viability of the advanced configurations. The pilot plant design, consisting of two integrated container-based units, has been completed. It includes downstream concentration up to 70 wt% H2O2. Installation, safety implementation, and regulatory approvals for the TRL6 pilot plant are currently underway.

Fortschritte, die über den aktuellen Stand der Technik hinausgehen und voraussichtliche potenzielle Auswirkungen (einschließlich der bis dato erzielten sozioökonomischen Auswirkungen und weiter gefassten gesellschaftlichen Auswirkungen des Projekts)

The Power2Hype project has achieved major advancements beyond the current state of the art in electrochemical H2O2 production. At laboratory scale, it validated a paired electrolysis concept enabling dual H2O2 formation at both electrodes, reaching combined efficiencies up to 200%. This approach represents a shift in oxidant synthesis and significantly reduces energy consumption per kilogram of H2O2 compared to conventional single-electrode processes.

In materials development, exceptional results were achieved with carbon-based catalysts delivering perfect selectivity toward hydrogen peroxide at industrially relevant current densities of 400 mA/cm², stably maintained over extended operation and surpassing typical literature values. A novel anion exchange membrane overcomes long-standing stability challenges, while a porous solid polymer electrolyte introduces an innovative manufacturing route with tunable properties beyond conventional materials. The integration of catalyst-coated membranes eliminates hazardous electrolytes, enhancing safety and product purity.

The project has progressed from laboratory to pre-industrial scale. The modular pilot plant design is among the larger electrochemical H2O2 systems currently under development worldwide. This work establishes a pathway toward multi-stack pilot operation, providing key insights for commercialization and demonstrating technical feasibility at scale.

From an environmental and economic perspective, the technology enables decentralized production, avoiding long-distance transport of concentrated H2O2. Integration with renewable electricity supports sustainable manufacturing, while on-site, on-demand production can be adapted to diverse industrial needs across a broad concentration range. Initial assessments indicate strong potential for reduced carbon footprint and competitive costs, particularly when combined with low-cost renewable power.

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