SUPREME project develops clean electrolysis technology, reducing iridium dependency by 75% while ending PFAS chemical use

European researchers have solved two of the biggest barriers preventing global adoption of green hydrogen technology: the reliance on toxic PFAS chemicals and the scarcity of expensive rare metals like iridium. The breakthrough, developed through the EU-funded SUPREME project, could democratize clean hydrogen production and accelerate the global transition to sustainable energy.

The innovation eliminates harmful per- and polyfluoroalkyl substances (PFAS) — the "forever chemicals" that persist in the environment and accumulate in living organisms — from the electrolysis process entirely. Simultaneously, the new technology reduces dependency on iridium, one of the rarest elements on Earth, by up to 75% while developing sophisticated recycling processes that can reclaim 90% of the iridium used.

This dual breakthrough addresses what many consider the Achilles' heel of green hydrogen: the environmental and economic costs of production technology. Traditional electrolysis systems often rely on PFAS chemicals for their durability and chemical resistance, while iridium serves as a catalyst in the most efficient electrolysis systems. Both create barriers to widespread deployment, particularly in developing economies.

The SUPREME team, led by researchers at the University of Southern Denmark, developed alternative materials and processes that maintain efficiency while eliminating problematic inputs. The PFAS-free approach uses innovative membrane technologies and environmentally benign chemical processes, while the iridium reduction comes through advanced catalyst design that maximizes performance with minimal material use.

Perhaps most importantly, the recycling breakthrough means that iridium becomes a renewable resource within the hydrogen production system. Rather than consuming rare metals, facilities can operate in a closed-loop system where catalysts are continuously recovered and reused, dramatically reducing both environmental impact and operating costs.

The timing couldn't be better. As governments worldwide commit to hydrogen strategies for decarbonization, these innovations remove key barriers to scaling production to meet ambitious climate targets. The technology is particularly significant for emerging economies, where access to rare materials and willingness to use toxic chemicals have limited clean energy options.

Key Facts

- Eliminates all PFAS ("forever chemicals") from electrolysis process
- Reduces iridium dependency by up to 75%
- Recovers 90% of iridium through advanced recycling
- Maintains efficiency comparable to traditional systems
- EU-funded SUPREME project led by University of Southern Denmark
- Technology ready for commercial demonstration

Why This Matters

The green hydrogen sector has experienced explosive growth as countries seek to decarbonize heavy industry, shipping, and other sectors difficult to electrify directly. However, environmental and supply chain concerns have limited deployment, particularly in regions without access to rare material markets or with strong environmental regulations.

PFAS chemicals became widespread in industrial applications because of their exceptional durability and chemical resistance. However, their persistence in the environment and bioaccumulation in organisms has led to increasing regulation. The EU has proposed broad restrictions on PFAS use, while several countries have banned specific applications.

Iridium scarcity presents a different challenge. Annual global production is only about 7 tons, while a full global hydrogen economy could require hundreds of tons annually. This supply-demand mismatch has driven iridium prices to over $4,000 per troy ounce, making it one of the most expensive materials on Earth.

The SUPREME project represents the kind of collaborative research that the EU framework programs are designed to foster — bringing together expertise from multiple countries and institutions to solve challenges too complex for individual organizations to tackle alone.

What We Don't Know Yet

The technology remains in the demonstration phase and hasn't been tested at commercial scale. Performance metrics in laboratory conditions may not translate directly to industrial operations, where factors like system integration, maintenance, and long-term durability become critical.

Cost analysis is preliminary, focusing on material costs rather than complete system economics. While eliminating PFAS and reducing iridium use should reduce costs, other components of the system may require premium materials that offset some savings.

The recycling process, while promising, requires sophisticated infrastructure that may not be available in all markets. Effective implementation depends on developing collection and processing networks that can economically recover and reprocess catalysts.

Regulatory approval processes for new chemical processes can be lengthy, particularly for systems intended to replace established technologies in industrial applications. Early adoption may be limited to markets with strong environmental incentives.

Competition from alternative technologies continues to evolve rapidly. Other research groups are developing different approaches to the same problems, and the SUPREME technology will need to prove advantages in real-world deployment.

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Published February 27, 2026 · Category: Science & Technology