FeNCy-PEM – Production and use of precious metal-free Fe-N-C catalysts

Development of a continuous, scalable production process and integration into the production and application of PEM fuel cell technology

In the FeNCy-PEM project, we are working with our partners to develop precious metal-free iron-nitrogen-carbon catalysts (Fe-N-C catalysts) for polymer electrolyte membrane fuel cells (PEM fuel cells). The aim is to establish a continuous and scalable manufacturing process and to integrate the materials into the production and application of PEM technology.

New catalysts for more economical PEM fuel cells

PEM fuel cells are an important technology for the use of hydrogen and for a climate-neutral energy supply. However, their widespread use has so far been limited by high costs. Platinum, which is used as a catalyst and is both cost-intensive and associated with dependencies on international supply chains, plays a key role here.

With FeNCy-PEM, we are tackling this challenge and developing Fe-N-C catalysts as a precious metal-free alternative for the cathode. The aim of the project is to make PEM technology more cost-effective, scalable and less dependent on critical raw materials in the long term.

From innovative material to scalable manufacturing process

The project focuses on the development of a continuous process for the production of Fe-N-C catalysts on a pilot scale. Graphene is converted into a catalytically active material by doping with iron and nitrogen. A plasma process in the gas phase is used, which enables the production of catalyst and carrier material in one step and thus creates good conditions for later scaling up.

The material produced is then further processed into an ink and made into cathodes and membrane electrode assemblies (MEA) in a scalable roll-to-roll process. FeNCy-PEM thus combines the development of the catalyst material directly with production tailored to the material.

Testing in the application and contribution to the value chain

In addition to production, the focus is on the application of the developed materials in the PEM fuel cell. The components manufactured in the project are tested for performance and durability in order to assess their suitability for practical use. In this way, FeNCy-PEM combines material development, process scaling and application testing along the value chain.

The project thus creates the basis for integrating platinum-free catalysts into fuel cell systems in the future and supporting the further development of hydrogen technology both economically and technologically.

Project information

Project acronym: FeNCy-PEM

Funding code: EFRE-20801377

Funding competition: Industry.IN.NRW innovation competition

Term: 1.12.2025 – 30.11.2028

Project partners:

Institut für Umwelt & Energie, Technik & Analytik e.V. (IUTA)
Westphalian University of Applied Sciences (WHS)
Laufenberg GmbH
ZBT – The Hydrogen and Fuel Cell Center
ProPuls GmbH (associated)

This project is funded by the European Union and the state of North Rhine-Westphalia as part of the ERDF/JTF program NRW 2021-2027.

Questions about the project

…will gladly answer

Oliver Pasdag

+49 203 7598-2211

o.pasdag@zbt.de

Any more questions?

Perhaps they know the answer

Adib Caidi

+49 203 7598-3123

a.caidi@zbt.de

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