• • The NiCoV electrode achieves an overpotential of only 253 mV at -400 mA cm−2, outperforming most Pt-based catalysts and enabling energy-efficient hydrogen production at industrial current densities.
• • Stability exceeds 200 hours at 400 mA cm−2, with no apparent degradation, ensuring long-term operational reliability for continuous industrial electrolysis.
• • In a scaled-up electrolyzer, the NiCoV cathode reduces cell voltage by 50 mV compared to commercial Raney nickel, leading to energy savings of 0.12 kWh per cubic meter of hydrogen produced.
• • For a medium-scale plant producing 1000 tons H2/year, the technology saves 1.33 × 10^6 kWh annually and cuts CO2 emissions by 770.26 tons, offering both economic and environmental benefits.