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Reference Number	NIA_WWU_02_61
Title	NextGen Electrolysis Producing Green Hydrogen from Contaminated Water
Status	Started
Energy Categories	Hydrogen and Fuel Cells (Hydrogen, Hydrogen production) 100%;
Research Types	Applied Research and Development 100%
Science and Technology Fields	ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering) 100%
UKERC Cross Cutting Characterisation	Not Cross-cutting 100%
Principal Investigator	Project Contact No email address given Wales and West Utilities
Award Type	Network Innovation Allowance
Funding Source	Ofgem
Start Date	01 August 2024
End Date	31 July 2025
Duration	ENA months
Total Grant Value	£432,134
Industrial Sectors	Energy
Region	Wales
Programme	Network Innovation Allowance
Investigators	Principal Investigator	Project Contact , Wales and West Utilities (100.000%)
	Industrial Collaborator	Project Contact , Wales and West Utilities (0.000%)
Web Site	https://smarter.energynetworks.org/projects/NIA_WWU_02_61
Objectives	HydroStar are partnering with WWU and Cardiff University to develop a game changing NextGen electrolysis technology within the SWIC which can directly use contaminated water for green hydrogen production on industrial sites, performing a remediation process and high efficiency hydrogen generation using the same device.The innovation is aimed at large gas users wishing to switch to hydrogen who also have large quantities of wastewater from onsite processes, removing the need for extensive purification and water main infrastructure to produce hydrogen more sustainably.This is achievable through electrocoagulation and particle flotation for water remediation, using bubble dynamics of electrolyser waste oxygen to bring contaminants to the surface with electrolysis of impure water achieved through bespoke membraneless electrolysis designs.This project will completely disrupt the current need for electrolysers to run off ultra-pure water sources by creating a system which can simultaneously remediate contaminated water and produce hydrogen from the remaining impure water. This will provide a resilient and flexible system which can operate in distributed locations without requiring extensive water/electrical grid infrastructure. Key innovations are;Combining remediation/production - Combining water treatment and hydrogen production into a single NextGen electrolysis device through advanced control systems for multi-use operationsCoagulation/flotation of contaminants - Combining hydrophobic/hydrophilic particles which grip onto contaminants and water respectively, with byproduct oxygen bubbles to float the contaminants particles to water surface where they can be removedElectrolysis of impure water - Using membraneless electrolysis to produce hydrogen from impure water, removing the need for water/energy intensive purification processesTo evidence the disruptive impact of a combined remediation/production system, a 5kW-scale system will be developed, using an optimised NextGen electrolyser design to enable coagulation/flotation of contaminant particles using Cardiff Universitys expertise in particle dynamics.GeneralThe following paragraphs outline how the project will meet measurement and data quality objectives, including the measurement procedures and techniques to be used against each Work Package (WP), and the mechanisms to ensure the traceability, reliability, and comparability of the measurement result. A data capture and handling framework is provided within the WP7 summary since this is the WP which contains the most data handling, however elements from this plan will be experienced within all of WPs 5,6 and 7).WP1 Project Management and ReportingWP1 involves several key tasks including establishing the baseline project management plan, risk management, and delivering reports / documentation, as well as any IP management.The Project Management and Reporting Work-Package will require careful management of any sensitive Intellectual Property (IP) data that may be required or developed as part of this project. HydroStar employees have been trained by its Senior Management Team to know the different types of IP, including but not limited to; patents, trademarks, copyrights, and trade secrets, allowing employees to understand how each type protects different aspects of prospective creations.Furthermore, HydroStar also work closely with their IP specialised Legal Team at Sirius IP, led by Kate Butler. Close communication with this organisation means that HydroStar regularly advised as to the best protection strategies and are kept up to date with the most contemporary changes regarding IP policy.Finally, HydroStar Senior Management only engage with third party companies when there is a Non-Disclosure Agreement (NDA) in place or a clear Collaboration Agreement (CA) that maps the ownership of the IP.WP2 Exploitation and DisseminationWP2 involves engagement with key stakeholders such as; Gas Users, Water Utilities, Local Authorities, and Councils. This will also involve approaching these organisations for potential water samples and consumption data.Therefore, this work package requires careful management of any sensitive data that may be required as part of this project. HydroStar employees will follow the most widely accepted conditions for managing Personally Identifiable Information (PII) as laid out in the General Data Protection Regulations (GDPR) such that employees safeguard individuals privacy. This will be ensured through the following steps:All HydroStar employees have been familiarised with GDPR requirements---ensures that all employees involved with this project are up to date with the regulatory requirements, preventing the likelihood of accidental data release.Data Minimisation---HydroStar employees will only collect PII data that is necessary, the team will also continually update data collection practices to avoid future unnecessary information collection.Data Retention and Deletion---HydroStar have clear data retention policies, ensuring that any PII that is no longer required is deleted. This deletion utilises secure erasure practices with second-stage backup systems adhering to HydroStar deletion protocols.Documentation and Accountability---HydroStars CFO, Ian Gordon (IG), is responsible for GDPR compliance, who regularly oversees updating policies. IG also maintains a detailed record of data processing activities and risk assessment development.WP3 Overall system architecture and operating conditionsWP3 involves assessing the overall operating conditions that the system will need to operate within both at the initial research scale but also in a scaled case. A core component of this work package is the sampling of wastewater sources, which will be analysed officially using laboratory testing to ensure quality of data. This will include heavy metals testing, microelement tests, biology tests and also microscope tests to view the microplastics. These tests will be achieved through a mix of external laboratories and Cardiff University lab equipment.WP4 CARDIFF UNIVERSITY WPTo be delivered by Cardiff University.WP5 Electrolyte analysis and pollutant capture systemsWithin WP5, the electrolyte composition will be modelled and calculated to ensure efficient operation of the system. The data used for this will be largely gained through HydroStars current patented electrolyte (B9TM and Bi-IonicTM). This provides the characteristics of the electrolyte, from which further development can be achieved.Alongside this, pollutant capture systems will be designed. A full literature review will be undertaken to ensure deep understanding of current systems is present. This will involve research papers, commercial systems and patent analyses, to ensure that the most effective solution can be utilised within the project but crucially without affecting any licenses or freedom to operate.WP6 Testing rig designs and manufactureWithin WP6 the testing rig will be designed and manufactured, using core information from previous work packages. The data generated will be from initial safety tests, which will be achieved through data logging systems to track temperatures within the device and also pressure, along with visual assessments. Visual recordings will be made to ensure data from this perspective is also present.WP7 Full testing procedure and performance analysisWP7 involves full testing and performance analysis of the electrolyser and pollutant skimming system. Therefore the data gained will be purely from the project, and as such high quality research data. The data from the system can be compared to market data, which will be achieved through conducting a literature review as well as some product analysis to determine the efficiency and resiliency associated with different electrolysers, including Solid Oxide, Proton Exchange Membrane, and Alkaline Electrolysers.A full data management and processing plan is being developed, consisting of the following elements;Data CaptureInstrumentation and DevicesData Entry and CollectionMetadata CaptureValidation and Quality ControlData Storage and ManagementData Storage SolutionsData OrganisationData SecurityData Processing and AnalysisData CleaningData IntegrationAnalytical Tools and Techniques (R, Python, SPSS)Data Sharing and ReportingData AccessibilityData DocumentationPublication and DisseminationData Archiving and PreservationLong-term Storage SolutionsData PreservationRetention PoliciesCompliance and Ethical ConsiderationsEthical Approval and ConsentData Protection RegulationsWP8 IP and patentingThe Project Management and Reporting Work-Package will require careful management of any sensitive Intellectual Property (IP) data that may be required or developed as part of this project. HydroStar employees have been trained by its Senior Management Team to know the different types of IP, including but not limited to; patents, trademarks, copyrights, and trade secrets, allowing employees to understand how each type protects different aspects of prospective creations.Furthermore, HydroStar also work closely with their IP specialised Legal Team at Sirius IP, led by Kate Butler. Close communication with this organisation means that HydroStar regularly advised as to the best protection strategies and are kept up to date with the most contemporary changes regarding IP policy.The project is rated low in the common assessment framework detailed in the ENIP document after assessing the total project value, the progression through the TRL levels, the number of project delivery partners and the high level of data assumptions. No additional peer review is required for this project. The project scope adopts a mix of running Work Packages (WPs) concurrently with a traditional waterfall model for specific work packages dependent on prior tasks being completed. The project consists of eight inter-linked work packagesWP1 - Project Management/ReportingCoordination of project and reporting using established PRINCE-2 techniques, assessing progress against milestones/deliverables, and periodically updating the risk registerWP2 - Exploitation/DisseminationWWU/HydroStar liaise with further clients/stakeholders to ensure outputs are commercially relevant and that broader dissemination of information occurs in further market verticalsWP3 - Overall system architecture/operating conditionsWhole system architecture, defining specific wastewater considerations and resultant electrolyser operating conditionsWP4 - Electrode designs/simulationsDesigns/simulation for electrode configurations which can facilitate flocculation/coagulation of pollutants, then electrolysis with remaining wastewater. Dependency from WP3WP5 - Electrolyte analysis and pollutant capture systemsDesigning electrolyte from specific wastewater ions/pollutants present, and physical/chemical skimming methods for pollutant clump removals. Dependency from WP3WP6 - Testing rig designs/manufactureDesign/manufacture testing rig which can simultaneously test flocculation/coagulation/electrolysis. Dependency from WP4/5WP7 - Full testing procedure and performance analysisTesting electrolysis/floatation/coagulation processes to assess efficiency and KPIs. Dependency from WP5/6WP8 - IP/patentingOngoing patent research/development by HydroStar to protect IP, achieving patent for filingThere is a lot of ongoing work to identify the most effective route to meet net zero in the UK and this project is one of many projects to evidence the major or minor role hydrogen will have in different scenarios. Repurposing the UK gas networks with hydrogen to support the challenge of the climate change act has the potential to savemillions with minimal gas customer disruption verses alternative decarbonisation solutions The objective of the project is to evidence, research and develop how different technologies for membraneless electrolysis can be used. The project objectives will look at how remediating industrial customers highly contaminated water and producing hydrogen from onsite water sources can help to enable more areas where hydrogen can be produced and injected on the network using the NextGen device.
Abstract	The UK Government has committed to reducing greenhouse gas emissions to net zero by 2050. All future energy modelling identifies a key role for hydrogen in providing decarbonised energy for heat, industry and power generation. Green hydrogen production requires carbon-free electricity, purified water and relatively expensive membranes made from rare metals giving considerable barriers to efficient and cost-effective production.This project will focus on how treatment of industrial manufacturing process wastewater containing elevated levels of contaminants (heavy metals/fibres) and microplastics, can expand water types available for electrolysis, increasing opportunities for co-location of electrolysis citing at industrial clusters and reducing risk of fast passivation of electrodes to reduce ongoing maintenance costs. The resultant water will be used in the process of electrolysis to produce green hydrogen, reducing cost and increasing availability of green hydrogen production.
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Added to Database	09/04/25