A recently published study presents a method that is faster and more economical than the conventional one for producing high-performance anodes for use in electrolyzers, equipment that generates hydrogen from the splitting of the water molecule. The work was carried out within the CINE Low-Carbon Hydrogen division.

In an electrolyzer, the anode is the electrode where oxygen is released. This reaction, called the oxygen evolution reaction, generates electrons and protons that are fundamental for hydrogen production at the cathode, but it requires large amounts of energy. For this reason, the presence of catalysts at the anode is necessary, and the more efficient the catalyst, the less energy is used in hydrogen production, reducing its cost and environmental impact.

The anode developed in this new work consists of a titanium substrate coated with a thin film of ruthenium and manganese oxides – a combination of materials that ensures high catalytic activity and durability. To arrive at the best “recipe,” the scientific team tested various oxide ratios and three heat treatment techniques (conventional furnace, microwave, and laser), analyzing the impact of the different options on the properties and performance of the resulting anodes.

The experiments proved that the alternative heating methods (microwave and laser) drastically reduce manufacturing time, resulting in lower energy consumption and, consequently, reduced electrode production costs. Furthermore, the study demonstrated that these heating techniques generate more active anodes for the oxygen evolution reaction. “The main contribution of this study was to demonstrate that the heating method used in the synthesis of these anodes exerts a strong influence on their structural, morphological, and electrocatalytic properties,” says Professor Elton Sitta (UFSCar), a CINE researcher who led the work.

The anodes were evaluated in two contexts that require very stable and active catalysts. Initially, they were tested under conditions similar to those found in proton exchange membrane electrolyzers, one of the most promising technologies for low-carbon hydrogen production. Subsequently, they were tested in real seawater – a particularly interesting water source because it avoids the consumption of potable water and utilizes a very abundant resource on the planet.

“The results showed that the films obtained by microwave and laser methods exhibit particularly interesting characteristics for future applications in electrolyzers operating in acidic and seawater media,” says Professor Elton.

The work brought together research groups from the Federal University of São Carlos (UFSCar), in the state of São Paulo, and the Tiradentes University (UNIT), in Sergipe. This partnership allowed for the combination of complementary skills, enabling a comprehensive study encompassing everything from material preparation to the detailed investigation of their properties and their application in real-world conditions. “This type of collaboration strengthens national research and contributes to the development of more efficient and sustainable technologies for the production of green hydrogen,” highlights Isabelle M. D. Gonzaga, a postdoctoral researcher at CINE who is the first author of the article.

According to Professor Elton, the alternative techniques used in this work have the potential to make anode manufacturing faster, more efficient, and more economically competitive. “From an industrial point of view, microwave heating seems to be the most easily adaptable alternative for large-scale production, while the use of lasers can be especially interesting in automated and continuous electrode manufacturing processes,” he explains.

The work was funded by FAPESP, Shell, CNPq, FINEP, and CAPES, in addition to strategic support from ANP.

Paper reference: Isabelle M.D. Gonzaga, Maria D.L. Santos, Roger Gonçalves, Lauren Moreti, Giancarlo R. Salazar-Banda, Katlin I.B. Eguiluz, Ernesto C. Pereira, Lucia H. Mascaro, Elton Sitta. Influence of the thermal synthesis method on the structure and electrocatalytic behavior of Ti/(RuO2)x(Mn3O4)1-x catalysts applied to acidic water oxidation. Electrochimica Acta, Volume 561, 2026. https://doi.org/10.1016/j.electacta.2026.148686

CINE members who participated in the work: Isabelle M. D. Gonzaga (postdoctoral researcher at UFSCar), Roger Gonçalves (postdoctoral researcher at UFSCar), Lauren Moreti (doctoral student at UFSCar), Ernesto C. Pereira (professor at UFSCar), Lucia H. Mascaro (professor at UFSCar), and Elton Sitta (professor at UFSCar).