Scientists at the University of Leicester have developed a novel recycling technique that could reshape the future of hydrogen fuel cell production while tackling the global challenge of “forever chemicals.”
The research team has devised a scalable method using sound waves and organic solvents to efficiently separate valuable platinum group metals and fluorinated polymer, also known as PFAS or per- and poly-fluoroalkyl substances, from catalyst-coated membranes.
These membranes are critical components in fuel cells and electrolysers used in hydrogen-powered vehicles and infrastructure.
PFAS, dubbed “forever chemicals” for their resistance to degradation, have come under increasing scrutiny for their persistence in the environment and potential health risks.
The Royal Society of Chemistry has called for urgent action to reduce PFAS contamination in the UK’s water supply.
A Cleaner and Simpler Recycling Process
“This method is simple and scalable,” said Dr. Jake Yang of the University of Leicester’s School of Chemistry. “We can now separate PFAS membranes from precious metals without harsh chemicals—revolutionizing how we recycle fuel cells.”
Traditional recycling has struggled with the strong adhesion between PFAS-based membranes and catalyst layers.
Leicester’s technique employs a two-step process: soaking the materials in an organic solvent followed by water ultrasonication, enabling the components to be delaminated without the need for toxic reagents.
Ultrasound Technology Accelerates Recovery
In a follow-up study, the team developed a continuous delamination system using a custom-designed sonotrode, a device that uses high-frequency ultrasound to create collapsing bubbles that rapidly separate the layers at room temperature.
The process is environmentally friendly and cost-effective, making it attractive for commercial adoption. The work was conducted in collaboration with Johnson Matthey, a leader in sustainable technology.
“The development of high-intensity ultrasound to separate catalyst-loaded membranes is a game-changer,” said Ross Gordon, principal research scientist at Johnson Matthey. “We are proud to collaborate on pioneering solutions that accelerate the adoption of hydrogen-powered energy while making it more sustainable.”
With demand for fuel cells rising amid the global push for decarbonization, the innovation offers a critical step forward in building a circular economy for clean energy technologies.
