Life Cycle Assessment of Closed-Loop Hydrometallurgical Recovery of Platinum Group Metals from PEM Fuel Cells and Electrolyzers

The rapid expansion of hydrogen technologies has intensified the demand for platinum group metals (PGMs), particularly platinum (Pt) and iridium (Ir). Proton exchange membrane fuel cells (PEMFCs) and proton exchange membrane water electrolyzers (PEMWEs) rely on PGMs and fluoropolymer membranes such as Nafion, generating increasing volumes of end-of-life (EoL) membrane electrode assemblies (MEAs). Conventional recycling routes are often energy-intensive, hazardous and limited in polymer recovery. In this study, a closed-loop hydrometallurgical recycling route is assessed through a life cycle assessment (LCA), supported by primary experimental data from optimized recycling trials. Mechanical delamination enabled separation of catalyst layers while preserving membranes, followed by a chlorine-based hydrometallurgical process operating under mild conditions. Leaching efficiencies exceeded 99% for Pt and 80% for Ir, demonstrating the feasibility of metal recovery. Two LCA models were developed: (i) a gate-to-gate recycling model for EoL MEAs and (ii) a cradle-to-gate manufacturing model comparing virgin and recycled Pt. Results showed that substituting virgin Pt with recycled Pt reduced the global warming potential of MEA manufacturing by up to 70%. The analysis also identified electricity demand and Nafion membrane waste as key environmental hotspots. Overall, the study highlights the potential of closed-loop recycling to enhance circularity in hydrogen technologies.