Tech watch: Cornell’s innovation could cut prices by 70%

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A compact solar-powered technology developed at Cornell University could apparently slash the cost of green hydrogen production by 70%, reaching $1 per kilogram within 15 years. That is a dramatic drop from today’s global average of $3 to $6 per kilogram, positioning the technology as a potential game-changer for affordable, scalable hydrogen.

• The technology operates similarly to conventional photovoltaics, which convert only about 30% of solar energy into electricity, with the rest lost as waste heat. Cornell’s system, however, captures this waste heat to evaporate seawater. 

• The steam condenses into clean water, which feeds an integrated electrolyser producing hydrogen alongside a potable water byproduct. This dual output tackles two critical challenges at once, significantly improving overall system efficiency.

More details

• Developed by a multidisciplinary team from MIT, Johns Hopkins University and Michigan State University, the technology currently produces 200 milliliters of hydrogen per hour with 12.6% energy efficiency by directly using natural sunlight to electrolyse seawater. 

• It also has the potential to be integrated into solar farms to cool photovoltaic panels, thereby enhancing their efficiency and extending their lifespan.

• The technology offers strong potential for Africa, where abundant sunlight and extensive coastlines create ideal conditions for seawater electrolysis. By producing both clean hydrogen and potable water, it tackles critical energy and water shortages prevalent across many regions. 

• Its compact, off-grid design makes it well-suited for remote and coastal communities, providing a scalable solution to support industrial development, clean transportation and climate resilience throughout the continent.

• The second quarter of 2025 also saw other technologies launched, including Bosch’s Hybrion PEM electrolysis stacks. Each stack operates at 1.25 megawatts and can produce up to 23 kilograms of hydrogen per hour Its modular design allows for flexible scalability, making it ideal for a wide range of applications—from small pilot projects to large-scale industrial hydrogen production.

• What sets the Hybrion stacks apart is their integration of cutting-edge digital technologies. With embedded sensors, power electronics and Bosch’s cloud-based monitoring platform, the system offers real-time operational optimisation and predictive maintenance. 

• German motion technology company Schaeffler launched a 1-megawatt electrolyser at Hannover Messe 2025, capable of producing around 450 kilograms of hydrogen per day. The system features scalable Proton Exchange Membrane (PEM) stacks ranging from 50 kW to 1 MW, alongside membrane-free versions for research and development, offering flexibility across different production scales and innovation environments.

• Schaeffler’s electrolyser stands out for its robust design and high power density, achieved through a large active cell area within the PEM stacks. This enhances both efficiency and reliability, making it well-suited for demanding applications, from decentralised commercial uses to large industrial production.

• The company has also introduced an innovative fuel cell stack that stands out due to its exceptionally low weight of less than 0.5 kg per kilowatt, making it significantly lighter than many existing fuel cell systems. This lightweight design is especially beneficial for e-mobility applications, where reducing weight directly improves vehicle efficiency, driving range and overall performance. 

• A notable technological advancement in this fuel cell stack is its advanced bipolar plate coating system, which can be customised to meet specific customer requirements. This tailored coating enhances durability and performance across diverse operating conditions, allowing Schaeffler to optimise the fuel cell for different vehicle types and environments, a flexibility rarely found in standard fuel cell products.

Our take

• If it materialises, Cornell University’s innovation could be a gamechanger for the green hydrogen sector, whose high production costs remain a major barrier to adoption. Replacing precious metals with cheaper alternatives would lower capital costs and make electrolysers more affordable globally.

• More broadly, it reflects a growing trend: Universities stepping up as key players in the hydrogen transition. With the right partnerships, academic breakthroughs like this could accelerate industrial uptake—especially in regions like Africa, where cost-effective solutions are critical.

• What stands out most is how these technologies blend digital intelligence with material innovation. From smart, cloud-connected systems to coatings that reduce reliance on precious metals, they reflect a shift toward smarter, cleaner and more adaptable hydrogen production—crucial for scaling green hydrogen in emerging markets.