Scalable Solutions for Green Hydrogen Production in South Africa

South Africa has abundant renewable energy sources such as sun and wind that can be used to produce clean and sustainable hydrogen. The country could therefore play an important role as a hydrogen producer for Germany and Europe in the future, provided that suitable infrastructure for hydrogen storage and distribution is developed and production costs can be reduced to remain competitive.

This is where the HySecunda joint project comes in, which is developing practical and scalable solutions for green hydrogen production in South Africa over a period of three years. The project is implementing capacity-building solutions, such as a training and education concept that addresses the country-specific needs of the 16 states comprising the Southern African Development Community (SADC region).

Another key focus for HySecunda is developing market- and system-compatible solutions for certifying green hydrogen and its derivatives. This is supported by energy system and economic analyses for production, supply chains, and industrial applications, which identify risks and necessary framework conditions at an early stage. These are prerequisites for successful commercialization and import to Germany and Europe.

At the technological level, the Fraunhofer Institutes provide support in four key areas:

• The development of innovative sensor technology, which, for example, will enable better detection of leaks in tanks and pipes and early detection of corrosion and aging processes.
• Innovative combined oxygen/hydrogen barrier layers. Such coatings prevent oxygen and hydrogen from penetrating into other parts of the electrolysis cell or into the environment. Improved solutions thus increase the service life and safety of the components used.
• More cost-effective coatings for bipolar plates (BPP). These plates serve as conductive partitions between the individual cells. Due to the extreme demands placed on these components (temperature, pressure, electrical voltage, corrosive conditions), BPPs are usually made of titanium, graphite, steel, or stainless steel, and the surface is additionally coated with precious metals such as gold or platinum. Here, the consortium aims to test more cost-effective solutions that can withstand the extreme operating conditions and offer the necessary long-term stability.
• Optimized solutions for porous transport layers (PTL). These support the efficient transport of gases, liquids, and ions in the electrolysis cell and are placed between the electrode and the bipolar plate. Optimized PTL solutions can significantly increase the efficiency of the reaction.