Composite PEM Electrolyser with Modified Nafion Membrane for Green Hydrogen Production Integrated with Solar-Wind Hybrid Renewable Systems

Green hydrogen — produced by electrolysis of water using renewable electricity with net-zero carbon emissions — is positioned at the centre of India's National Green Hydrogen Mission (NGHM), which targets 5 Mt/yr green hydrogen production capacity by 2030 at a cost below USD 1/kg, driving an estimated USD 100 billion in investment across electrolysis, storage, and utilisation infrastructure. Proton Exchange Membrane (PEM) electrolysers, which offer high current density operation (1-3 A/cm²), fast dynamic response compatible with intermittent renewable power input, and compact modular form factor, are the preferred technology for the distributed small-scale (100 kW-10 MW) segment of India's green hydrogen market — particularly for co-located renewable-electrolyser installations at solar parks in Rajasthan, Gujarat, and Tamil Nadu. This paper presents a composite membrane electrode assembly (MEA) for PEM electrolysis incorporating a Nafion-ZrO₂ nanocomposite membrane (15 wt% ZrO₂, 2.1% crosslinking density) that reduces ohmic resistance by 38% relative to standard Nafion-117 through improved proton conductivity at 80°C operating temperature, while maintaining mechanical integrity and chemical stability under the differential pressure conditions of pressurised hydrogen production. Polarisation curve characterisation, electrochemical impedance spectroscopy (EIS) Nyquist analysis, faradaic efficiency measurement, and 200-hour durability testing at 1 A/cm² are reported. A 100 kW hybrid solar-wind-electrolyser system model is designed for a Bikaner, Rajasthan site, with LCOH sensitivity analysis and monthly renewable generation-hydrogen dispatch profiles determining the optimal system configuration. The Newcastle University collaboration contributes the ZrO₂ nanoparticle surface functionalisation protocol that achieves the required Nafion-matrix compatibility.