Evonik has launched production of a high-performance membrane at a new pilot plant in Marl, North Rhine-Westphalia—marking a major step toward cheaper, scalable green hydrogen.
The facility is now producing the polymer membrane at commercial scale, with capacity for electrolyzer deployment of up to 2.5 gigawatts per year. That alone represents roughly one quarter of Germany’s planned electrolysis capacity for 2030.
The development comes as demand for green hydrogen is expected to surge over the coming decades as industries move to cut emissions. Hydrogen is increasingly seen as a critical energy carrier and industrial feedstock for steel and chemical production.
But cost remains a major barrier: today, green hydrogen is estimated to be two to four times more expensive than fossil-derived “gray” hydrogen, driven by electricity costs and the economics of electrolysis systems.
Evonik is betting on AEM electrolysis (Anion Exchange Membrane) as a way to change that equation. The company has developed a key component for the process—the anion-conducting DURAION membrane.
“Our membrane delivers high performance while reducing investment costs, enabling the innovative AEM technology to achieve a breakthrough in hydrogen production,” says Christian Däschlein, Head of the New Growth Area AEM in Evonik’s Innovation Factory.
Together with experts from the High Performance Polymers business line, his team developed the high-performance membrane specifically for AEM electrolysis.
AEM technology is gaining traction in Europe and Asia because it operates in an alkaline environment, allowing the use of lower-cost, precious-metal-free materials. Industry studies suggest it could cut investment costs by at least 25 percent.
It also enables hydrogen to be produced under pressure, reducing the need for additional compression systems, and offers flexibility to integrate with intermittent renewable power such as wind and solar.
The DURAION membrane is central to that promise. It combines high ion conductivity with strong chemical and mechanical stability, improving efficiency and extending service life. It also ensures reliable separation of hydrogen and oxygen, preventing the formation of explosive gas mixtures. Designed for high current densities and pressure operation, the membrane is produced without PFAS additives.
The Marl facility represents Evonik’s shift from laboratory development to continuous industrial production. The coating line—nearly 20 meters long—is among the largest of its kind globally, capable of producing membranes up to one meter wide for large-scale electrolyzers.
“Our strength lies in complete backward integration—from the starting molecules to the finished membrane roll. This allows us not only to deliver large volumes but also to ensure excellent product performance with consistently high quality,” says Däschlein.
The system can also embed fabric reinforcement for large-scale applications.
Early manufacturers of AEM electrolyzers are already deploying DURAION membranes in pilot and demonstration systems.
Momentum is also building internationally, particularly in China, where AEM technology is advancing rapidly.
To support this, Evonik has opened the AEM Center Shanghai, its first application-focused technology hub in Asia. The center tests Marl-produced membranes under real operating conditions with local partners, aiming to accelerate commercialization and integration into hydrogen infrastructure.
Together, the Marl pilot plant and Shanghai center signal Evonik’s push to move AEM electrolysis from promising technology to industrial reality—at a time when the race to scale clean hydrogen is intensifying globally.