GREEN HYDROGEN / ELECTROLYSIS
Electrolysis materials
We are creating the materials underpinning the clean energy transition. Our products increase the performance of water and CO₂ electrolysers - replacing inefficient porous components such as metallic meshes, felts, sintered metal powders, and conventional metal foams.
The problem with today's hydrogen
Hydrogen is indispensable. It underpins fertilizer production, industrial chemistry, and the refining of fuels. The global hydrogen market is worth over $200 billion, but nearly all of it is "grey" hydrogen produced through steam methane reforming. For every tonne of grey hydrogen produced, between 9 and 14 tonnes of CO₂ are released, accounting for nearly 2% of global greenhouse gas emissions.
Green hydrogen, produced by splitting water using renewable electricity, offers a near-zero-emission alternative at the point of production. It can directly replace grey hydrogen and open pathways to decarbonizing steel, aviation, and shipping. Sectors where electrification alone falls short. The barrier is cost. Inefficient electrolyser components keep green hydrogen expensive and limit its deployment at scale.
Where Apheros comes in
The porous transport layers inside electrolysers (metallic meshes, felts, sintered powders, conventional metal foams) are a primary bottleneck. They restrict gas and liquid co-transport, underutilize catalyst surface area, and degrade under sustained operating conditions.
Apheros replaces them.
Our nickel-based foam electrodes are purpose-built for water electrolysis, engineered for both Alkaline (AWE) and Anion Exchange Membrane (AEM) systems. They are manufactured from abundant materials, eliminating dependence on expensive noble metals, and produced through a scalable process designed for GW-scale electrode supply.
Performance
Nickel foam electrodes, validated against current benchmarks.
- Lowest operating voltage at high current densities in AEM electrolysis
- Demonstrated in internal benchmark testing against commercially available porous transport materials
- Ultra-high surface area (>1,000,000 m²/m³)
- Higher catalyst utilisation with lower noble metal loading
- Fully open, hierarchical microstructure
- Optimises gas/liquid co-transport and reduces mass transport overpotential
- 20-50% efficiency improvement over commercially available porous transport materials in AWE and AEM systems, based on internal performance validation
- Scalable manufacturing
- Process designed for industrial-volume electrode supply from day one
Working toward affordable green hydrogen
Apheros foam electrodes are designed to reduce system-level electrolyser costs, making green hydrogen economically competitive with grey, not just technically feasible. We are actively engaged with electrolyser developers and are open to pilot agreements and co-development partnerships.
Ready to start into a greener future together?