Breakthrough in fuel cell recycling turns ‘forever chemicals’ into renewable resources

A team of scientists at the University of Leicester has developed a groundbreaking technique that uses soundwaves to separate materials in fuel cells within seconds, marking a significant advancement in clean energy technology. This innovation has the potential to transform how fuel cells are recycled, making the process both sustainable and economically viable.

The new method addresses a major environmental concern related to per- and polyfluoroalkyl substances (PFAS), often dubbed "forever chemicals" due to their resistance to degradation. These chemicals, commonly used in catalyst-coated membranes (CCMs) within fuel cells and water electrolysers, are known to contaminate drinking water and pose serious health risks. The Royal Society of Chemistry has called for government action to reduce PFAS levels in the UK water supply.

Fuel cells, which are integral to hydrogen-powered transportation systems such as cars, trains, and buses, rely on CCMs that contain precious platinum group metals. Until now, the strong bond between catalyst layers and PFAS membranes has posed a major obstacle to effective recycling. The University of Leicester team overcame this by developing a scalable approach that combines organic solvent soaking with water-based ultrasonication, enabling efficient separation of these materials without the use of harsh chemicals.

Dr. Jake Yang from the University’s School of Chemistry explained that the method simplifies fuel cell recycling and enhances sustainability. “We can now separate PFAS membranes from precious metals without harsh chemicals—revolutionising how we recycle fuel cells,” he said. “Fuel cells have long been considered a breakthrough technology for clean energy, but the high cost of platinum group metals has been a barrier. A circular economy for these materials brings that breakthrough closer to reality.”

Further advancing their research, the team introduced a continuous delamination process using a specially designed blade sonotrode. This device employs high-frequency ultrasound to split the membranes at room temperature. The process generates microbubbles that collapse under pressure, allowing for the rapid separation of valuable catalysts in just seconds. This innovation could significantly accelerate the recycling process and support the broader adoption of hydrogen-powered energy systems.

The research was conducted in partnership with Johnson Matthey, a global leader in sustainable technologies. This collaboration between academia and industry highlights the importance of joint efforts in pushing the boundaries of clean energy solutions.

Ross Gordon, Principal Research Scientist at Johnson Matthey, praised the development as a "game-changer" in fuel cell recycling. “We are proud to collaborate on pioneering solutions that accelerate the adoption of hydrogen-powered energy while making it more sustainable and economically viable,” he said.

With global demand for fuel cells on the rise, this breakthrough supports the transition to a circular economy by enabling the efficient recycling of vital components. The University of Leicester’s innovation not only reduces the environmental impact of PFAS but also makes fuel cell technology more accessible and cost-effective, paving the way for a greener, more sustainable energy future.