The stability challenge on the pathway to high-current-density polymer electrolyte membrane water electrolyzers

Degradation of PGM and PGM-free Coatings on PEMWE Porous Transport Layers

A good and long-term stable electrical contact between the porous anode transport layer (PTL) and the adjacent catalyst layer is essential for efficient polymer electrolyte membrane water electrolyzers. This study describes the extensive comparison of seven titanium passivation-protecting coatings using short- and long-term measurements for at least 2000 h. The measurements are supported by before and after scanning electron microscope investigations of cross sections, energy-dispersive X-ray spectroscopy, X-ray diffractometry of the coatings, contact resistance measurements, and ex situ rapid aging tests. Overall, iridium and platinum PTL coatings offer outstanding contact and excellent corrosion protection. Compared to the uncoated reference sample, platinum shows a 93% reduction in the overall degradation rate to 7 μV h-1 (at a current density of 3 A cm-2) over 5000 h and even reduces ohmic overvoltages over time in the first 2000 h. Interestingly, the interface to the flow field does not appear to be influenced by precious metal coatings and, hence, does not need to be coated. In contrast, niobium and titanium nitride PTL coatings under investigation do not provide an improvement compared to the uncoated reference but show dissolution and oxidation phenomena, respectively. Titanium hydride produced by hydrochloric acid improves the electrical contact and reduces degradation by 49% overall and 62% in terms of ohmic overvoltages compared to the uncoated reference. It also shows a saturation behavior in degradation with a stable rate of 23 μV h-1 in the second 1000 h of the measurement. Ex situ rapid aging tests additionally support the main trends. For all surface treatments, more detailed information about the occurring aging mechanisms and reversible overvoltages is obtained by separating the degradation rate into partial rates of the overvoltage mechanisms.

Proton Exchange Membrane (PEM) Water Electrolysis: Cell-Level Considerations for Gigawatt-Scale Deployment

Hydrogen produced with no greenhouse gas emissions is termed "green hydrogen" and will be essential to reaching decarbonization targets set forth by nearly every country as per the Paris Agreement. Proton exchange membrane water electrolyzers (PEMWEs) are expected to contribute substantially to the green hydrogen market. However, PEMWE market penetration is insignificant, accounting for less than a gigawatt of global capacity. Achieving substantive decarbonization via green hydrogen will require PEMWEs to reach capacities of hundreds of gigawatts by 2030. This paper serves as an overarching roadmap for cell-level improvements necessary for gigawatt-scale PEMWE deployment, with insights from three well-established hydrogen technology companies included. Analyses will be presented for economies of scale, renewable energy prices, government policies, accelerated stress tests, and component-specific improvements.

The smallest electrochemical bubbles

Many of the relevant electrochemical processes in the context of catalysis or energy conversion and storage, entail the production of gases. This often implicates the nucleation of bubbles at the interface, with the concomitant blockage of the electroactive area leading to overpotentials and Ohmic drop. Nanoelectrodes have been envisioned as assets to revert this effect, by inhibiting bubble formation. Experiments show, however, that nanobubbles nucleate and attach to nanoscale electrodes, imposing a limit to the current, which turns out to be independent of size and applied potential in a wide range from 3 nm to tenths of microns. Here we investigate the potential-current response for disk electrodes of diameters down to a single-atom, employing molecular simulations including electrochemical generation of gas. Our analysis reveals that nanoelectrodes of 1 nm can offer twice as much current as that delivered by electrodes with areas four orders of magnitude larger at the same bias. This boost in the extracted current is a consequence of the destabilization of the gas phase. The grand potential of surface nanobubbles shows they can not reach a thermodynamically stable state on supports below 2 nm. As a result, the electroactive area becomes accessible to the solution and the current turns out to be sensitive to the electrode radius. In this way, our simulations establish that there is an optimal size for the nanoelectrodes, in between the single-atom and ∼3 nm, that optimizes the gas production.

Similarities and Differences between Gas Diffusion Layers Used in Proton Exchange Membrane Fuel Cell and Water Electrolysis for Material and Mass Transport

Proton-exchange membrane fuel cells (PEMFCs) and water electrolysis (PEMWE) are rapidly developing hydrogen energy conversion devices. Catalyst layers and membranes have been studied extensively and reviewed. However, few studies have compared gas diffusion layers (GDLs) in PEMWE and PEMFC. This review compares the differences and similarities between the GDLs of PEMWE and PEMFC in terms of their material and mass transport characteristics. First, the GDL materials are selected based on their working conditions. Carbon materials are prone to rapid corrosion because of the high anode potential of PEMWEs. Consequently, metal materials have emerged as the primary choice for GDLs. Second, the mutual counter-reactions of the two devices result in differences in mass transport limitations. In particular, water flooding and the effects of bubbles are major drawbacks of PEMFCs and PEMWE, respectively; well-designed structures can solve these problems. Imaging techniques and simulations can provide a better understanding of the effects of materials and structures on mass transfer. Finally, it is anticipated that this review will assist research on GDLs of PEMWE and PEMFC.

Numerical Investigation of the Performance of a Proton Exchange Membrane Water Electrolyzer under Various Outlet Manifold Structure Conditions

The oxygen discharge process significantly affects the electrochemical performance of a proton exchange membrane water electrolyzer (PEMWE), which requires an optimal structure of the flow field implemented in the bipolar plate (BP) component. In this study, we numerically investigated the two-phase (liquid water and oxygen) flow in the PEMWE's channel region with different outlet manifold structures utilizing the volume of fluid (VOF) model. Then, the oxygen volume fraction at the liquid/gas diffusion layer (L/GDL) surface, i.e., the interface of the channel and L/GDL, obtained by the liquid water and oxygen flow model was incorporated into a three-dimensional (3D) PEMWE model, which made it possible to predict the influence of the outlet manifold structure on the multiple transfers inside the whole electrolyzer as well as the electrochemical performance. The results indicate that the existence of oxygen in the flow field significantly decreased the electrolyzer voltage at a fixed operation current density and deteriorated the uniform distribution of the oxygen amount, current density (corresponding to the electrochemical reaction rate) and temperature in the membrane electrode assembly (MEA), indicating that the rapid oxygen removal from the flow field is preferred in the operation of the electrolyzer. Moreover, slight increases in the width of the outlet manifold were helpful in relieving the oxygen accumulation in the anode CL and, hence, improved the electrolyzer performance with more uniform distribution characteristics.

Recent advances in proton exchange membrane water electrolysis

Proton exchange membrane water electrolyzers (PEMWEs) are an attractive technology for renewable energy conversion and storage. By using green electricity generated from renewable sources like wind or solar, high-purity hydrogen gas can be produced in PEMWE systems, which can be used in fuel cells and other industrial sectors. To date, significant advances have been achieved in improving the efficiency of PEMWEs through the design of stack components; however, challenges remain for their large-scale and long-term application due to high cost and durability issues in acidic conditions. In this review, we examine the latest developments in engineering PEMWE systems and assess the gap that still needs to be filled for their practical applications. We provide a comprehensive summary of the reaction mechanisms, the correlation among structure-composition-performance, manufacturing methods, system design strategies, and operation protocols of advanced PEMWEs. We also highlight the discrepancies between the critical parameters required for practical PEMWEs and those reported in the literature. Finally, we propose the potential solution to bridge the gap and enable the appreciable applications of PEMWEs. This review may provide valuable insights for research communities and industry practitioners working in these fields and facilitate the development of more cost-effective and durable PEMWE systems for a sustainable energy future.

Environmental and economic potential of decentralised electrocatalytic ammonia synthesis powered by solar energy

Intense efforts have been devoted to developing green and blue centralised Haber-Bosch processes (gHB and bHB, respectively), but the feasibility of a decentralised and more sustainable scheme has yet to be assessed. Here we reveal the conditions under which small-scale systems (NH3-leaves) based on the electrocatalytic reduction of nitrogen (eN2R) powered by photovoltaic energy could realise a decentralised scheme competitive in terms of environmental and economic criteria. For this purpose, we calculated energy efficiency targets worldwide, providing clear values that may guide research in the incipient eN2R field. Even at this germinal stage, the NH3-leaf technology would compete favourably in sunny locations for CO2-related Earth-system processes and human health relative to the business-as-usual production scenario. Moreover, a modest 8% gain in energy efficiency would already make them outperform the gHB in terms of climate change-related impacts in the sunniest locations. If no CO2 taxation is enforced, the lowest estimated ammonia production cost would be 3 times the industrial standard, with the potential to match it provided a substantial decrease of investment costs and very high selectivity toward ammonia in eN2R are achieved. The disclosed sustainability potential of NH3-leaf makes it a strong ally of gHB toward defossilised ammonia production.

The thermodynamic and life-cycle assessments of a novel charging station for electric vehicles in dynamic and steady-state conditions

The current study performs the thermodynamic and life-cycle assessments (LCA) of a novel charging station in two system designs. The goal is to design an efficient charging station for electric vehicles with high efficiencies and low environmental impacts using Solid Oxide Fuel Cell (SOFC) technology. SOFC is considered a sustainable and environmentally friendly technology to generate electricity compared to combustion engines. To ameliorate the performance, the exhaust heat of the SOFC stacks will be recovered for hydrogen production in an electrolyzer. The system uses four SOFCs to charge the electric vehicles while the output heat is recovered by an Organic Rankine Cycle (ORC) to generate further electricity for hydrogen production in an electrolyzer. In the first design, it is assumed that the SOFC stacks will work full-load during the 24 h of the day, while the second design considers full-load operation for 16 h and part-load (30%) operation for 8 h. The second design of the system analyzes the possibility of integrating a [Formula: see text] lithium-ion battery stores the excessed electricity once the power load is low and acts as a backup in high power demands. Results of the thermodynamic analysis calculated the overall efficiencies of 60.84% and 60.67% for the energy and exergy, respectively, with the corresponding power and hydrogen production of 284.27 kWh and 0.17 g/s. It was observed that higher current density would increase the output of SOFC while reducing the overall energy and exergy efficiencies. In dynamic operation, the use of the batteries can well balance the change of the power loads and improve the dynamic response of the system to the simultaneous changes in the power demand. LCA results also showed that the 284.27kWh system leads to global warming (kg [Formula: see text] eq) of 5.17E+05, 4.47E+05, and 5.17E+05 using Solid Oxide Electrolyzer (SOE), Proton Exchange Membrane Electrolyzer (PEME), and Alkaline Electrolyzer (ALE), respectively. In this regard, the usage of PEME has the lowest impact on the environment in comparison to SOEC, and ALE. A comparison between the environmental impacts of different ORC's working fluids also suggested against the usage of R227ea while R152a showed promising results to be used in the system. The size and weight study also revealed that the battery benefits from the lowest volume and weight in comparison to the other components. Among the considered components in this study, the SOFC unit and the PEME have by far the highest volume.

Electrochemically Grown Ultrathin Platinum Nanosheet Electrodes with Ultralow Loadings for Energy-Saving and Industrial-Level Hydrogen Evolution

Nanostructured catalyst-integrated electrodes with remarkably reduced catalyst loadings, high catalyst utilization and facile fabrication are urgently needed to enable cost-effective, green hydrogen production via proton exchange membrane electrolyzer cells (PEMECs). Herein, benefitting from a thin seeding layer, bottom-up grown ultrathin Pt nanosheets (Pt-NSs) were first deposited on thin Ti substrates for PEMECs via a fast, template- and surfactant-free electrochemical growth process at room temperature, showing highly uniform Pt surface coverage with ultralow loadings and vertically well-aligned nanosheet morphologies. Combined with an anode-only Nafion 117 catalyst-coated membrane (CCM), the Pt-NS electrode with an ultralow loading of 0.015 mgPt cm-2 demonstrates superior cell performance to the commercial CCM (3.0 mgPt cm-2), achieving 99.5% catalyst savings and more than 237-fold higher catalyst utilization. The remarkable performance with high catalyst utilization is mainly due to the vertically well-aligned ultrathin nanosheets with good surface coverage exposing abundant active sites for the electrochemical reaction. Overall, this study not only paves a new way for optimizing the catalyst uniformity and surface coverage with ultralow loadings but also provides new insights into nanostructured electrode design and facile fabrication for highly efficient and low-cost PEMECs and other energy storage/conversion devices.

Effects of Artificial River Water on PEM Water Electrolysis Performance

Hydrogen, a clean and renewable energy source, is a promising substitute for fossil fuels. Electricity-driven water electrolysis is an attractive pathway for clean hydrogen production. Accordingly, the development of electrolysis cells has drawn researchers’ attention to capital costs related to noble catalyst reduction and membrane degradation by the contaminations. In the literature, polymer electrolyte membranes (PEMs) have been studied on single cations contamination. In this study, we investigated the performance of a PEM on monovalent and divalent cation contamination by feed water. Artificial river water, called soft water, was used to analyze the effect of impurities on the PEM. The results demonstrated that the operating voltage drastically increased and induced cell failure with increasing Mg2+ and Ca2+ concentrations; however, it did not increase for Na+ and K+ after increase in voltage. Therefore, divalent cations have a stronger affinity than monovalent cations to degrade PEM and should be effectively excluded from the feed water.

Bifunctional and Self-Supported NiFeP-Layer-Coated NiP Rods for Electrochemical Water Splitting in Alkaline Solution

Designing efficient and robust nonprecious metal-based electrocatalysts for overall water electrolysis, which is mainly limited by the oxygen evolution reaction (OER), for hydrogen production remains a major challenge for the hydrogen economy. In this work, a bimetallic NiFeP catalyst is coated on nickel phosphide rods grown on nickel foam (NiFeP@NiP@NF). This self-supported and interfacially connected electrode structure is favorable for mass transfer and reducing electrical resistance during electrocatalysis. The preparation of NiFeP@NiP@NF is optimized in terms of (i) the coprecipitation time of the NiFe Prussian blue analogue layer that serves as phosphides precursor and (ii) the phosphidation temperature. The optimized sample exhibits excellent OER performance delivering current densities of 10 and 100 mA cm^-2 at low overpotentials of 227 and 252 mV in 1.0 M KOH, respectively, and maintaining 10 mA cm^-2 for more than 120 h without obvious degradation. Moreover, it can also be operated as a hydrogen evolution electrocatalyst, requiring an overpotential of 105 mV at 10 mA cm^-2 in the same medium. Thus, the as-prepared material was tentatively utilized as a bifunctional electrocatalyst in a symmetric electrolyzer, requiring a voltage bias of 1.57 V to afford 10 mA cm^-2 in 1.0 M KOH, while exhibiting outstanding stability.

Constructing a Multifunctional Interface between Membrane and Porous Transport Layer for Water Electrolyzers

The cell performance and durability of polymer electrolyte membrane (PEM) water electrolyzers are limited by the surface passivation of titanium-based porous transport layers (PTLs). In order to ensure stable performance profiles over time, large amounts (≥1 mg·cm^-2) of noble metals (Au, Pt, Ir) are most widely used to coat titanium-based PTLs. However, their high cost is still a major obstacle toward commercialization and widespread application. In this paper, we assess different loadings of iridium, ranging from 0.005 to 0.05 mg·cm^-2 in titanium PTLs, that consequently affect the investment costs of PEM water electrolyzers. Concerning a reduction in the precious metal costs, we found that Ir as a protective layer with a loading of 0.025 mg·cm^-2 on the PTLs would be sufficient to achieve the same cell performance as PTLs with a higher Ir loading. This Ir loading is a 40-fold reduction over the Au or Pt loading typically used for protective layers in current commercial PEM water electrolyzers. We show that the Ir protective layer here not only decreases the Ohmic resistance significantly, which is the largest part of the gain in performance, but moreover, the oxygen evolution reaction activity of the iridium layer makes it promising as a cost-effective catalyst layer. Our work also confirms that the proper construction of a multifunctional interface between a membrane and a PTL indeed plays a crucial role in guaranteeing the superior performance and efficiency of electrochemical devices.

On the limitations in assessing stability of oxygen evolution catalysts using aqueous model electrochemical cells

Recent research indicates a severe discrepancy between oxygen evolution reaction catalysts dissolution in aqueous model systems and membrane electrode assemblies. This questions the relevance of the widespread aqueous testing for real world application. In this study, we aim to determine the processes responsible for the dissolution discrepancy. Experimental parameters known to diverge in both systems are individually tested for their influence on dissolution of an Ir-based catalyst. Ir dissolution is studied in an aqueous model system, a scanning flow cell coupled to an inductively coupled plasma mass spectrometer. Real dissolution rates of the Ir OER catalyst in membrane electrode assemblies are measured with a specifically developed, dedicated setup. Overestimated acidity in the anode catalyst layer and stabilization over time in real devices are proposed as main contributors to the dissolution discrepancy. The results shown here lead to clear guidelines for anode electrocatalyst testing parameters to resemble realistic electrolyzer operating conditions.

Two-Dimensional Molybdenum Diselenide Tuned by Bimetal Co/Ni Nanoparticles for Oxygen Evolution Reaction

Herein, we report fabrication of MoSe2 functionalized with bimetal Co/Ni particles, which shows promising electrochemical performance in oxygen and hydrogen evolution reactions (OER and HER) due to its physicochemical properties such as electronic configuration and great electrochemical stability. We propose functionalization with two transition metals, cobalt and nickel, expecting a synergic effect in electrocatalytic activity in a water splitting reaction. These electrocatalytic reactions are essential for efficient electrochemical energy storage. The thin flakes were obtained by exfoliation of bulk molybdenum diselenide. Next, after deposition of metals, precursors were carbonized. Electrochemical data reveal that the presence of Ni and Co particles boosts electrocatalyst performance, providing a great number of active sites due to their conductivity. Interestingly, the material exhibited great evolution potential and good stability in long-term tests.

Perspectives on Low-Temperature Electrolysis and Potential for Renewable Hydrogen at Scale

Hydrogen is an important part of any discussion on sustainability and reduction in emissions across major energy sectors. In addition to being a feedstock and process gas for many industrial processes, hydrogen is emerging as a fuel alternative for transportation applications. Renewable sources of hydrogen are therefore required to increase in capacity. Low-temperature electrolysis of water is currently the most mature method for carbon-free hydrogen generation and is reaching relevant scales to impact the energy landscape. However, costs still need to be reduced to be economical with traditional hydrogen sources. Operating cost reductions are enabled by the recent availability of low-cost sources of renewable energy, and the potential exists for a large reduction in capital cost withmaterial and manufacturing optimization. This article focuses on the current status and development needs by component for the low-temperature electrolysis options.