Low-Cost and Durable Bipolar Plates for Proton Exchange Membrane Electrolyzers

Recent Advances in Polymer Electrolyte Membrane Water Electrolyzer Stack Development Studies: A Review

Polymer electrolyte membrane water electrolyzers have significant advantages over other electrolyzers, such as compact design, high efficiency, low gas permeability, fast response, high-pressure operation (up to 200 bar), low operating temperature (20-80 °C), lower power consumption, and high current density. Moreover, polymer electrolyte membrane water electrolyzers are a promising technology for sustainable hydrogen production due to their easy adaptability to renewable energy sources. However, the cost of expensive electrocatalysts and other construction equipment must be reduced for the widespread usage of polymer electrolyte membrane water electrolyzer technology. In this review, recent improvements made in developing the polymer electrolyte membrane water electrolyzer stack are summarized. First, we present a brief overview of the working principle of polymer electrolyte membrane water electrolyzers. Then, we discuss the components of polymer electrolyte membrane water electrolyzers (base materials such as membranes, gas diffusion layers, electrocatalysts, and bipolar plates) and their particular functions. We also provide an overview of polymer electrolyte membrane water electrolyzer's material technology, production technology, and commercialization issues. We finally present recent advancements of polymer electrolyte membrane water electrolyzer stack developments and their recent developments under different operating conditions.

Stability of electrocatalytic OER: from principle to application

Hydrogen energy, derived from the electrolysis of water using renewable energy sources such as solar, wind, and hydroelectric power, is considered a promising form of energy to address the energy crisis. However, the anodic oxygen evolution reaction (OER) poses limitations due to sluggish kinetics. Apart from high catalytic activity, the long-term stability of electrocatalytic OER has garnered significant attention. To date, several research studies have been conducted to explore stable electrocatalysts for the OER. A comprehensive review is urgently warranted to provide a concise overview of the recent advancements in the electrocatalytic OER stability, encompassing both electrocatalyst and device developments. This review aims to succinctly summarize the primary factors influencing OER stability, including morphological/phase change and electrocatalyst dissolution, as well as mechanical detachment, alongside chemical, mechanical, and operational degradation observed in devices. Furthermore, an overview of contemporary approaches to enhance stability is provided, encompassing electrocatalyst design (structural regulation, protective layer coating, and stable substrate anchoring) and device optimization (bipolar plates, gas diffusion layers, and membranes). Hopefully, more attention will be paid to ensuring the stable operation of electrocatalytic OER and the future large-scale water electrolysis applications. This review presents design principles aimed at addressing challenges related to the stability of electrocatalytic OER.

Corrosion behavior of Ti-Pt-coated stainless steel for bipolar plates in polymer electrolyte membranes under water electrolysis conditions

In this study, the corrosion behavior and degradation mechanism of Ti-Pt-coated stainless steel bipolar plates were investigated through electrochemical tests and surface analysis in a polymer electrolyte membrane water electrolysis (PEMWE) operating environment. The coated bipolar plate has a corrosion current density of only 1.68 × 10-8 A/cm2, which is an order of magnitude lower than that of the bare SS316L substrate (1.94 × 10-7 A/cm2), indicating that its corrosion resistance is superior to that of bare SS316L substrate. However, in the PEMWE operating environment, the protection efficiency of the coating and the corrosion resistance of the coated bipolar plate decreased. The degradation of the coated bipolar plate can be attributed to electrolyte penetration into the blistering areas of the coating layer with micro voids. Defects in the coating layer occur because of the pressure of oxygen gas generated within the coating layer under high-potential conditions, thereby exposing the substrate to the electrolyte and corrosion.

Alternative to Conventional Solutions in the Development of Membranes and Hydrogen Evolution Electrocatalysts for Application in Proton Exchange Membrane Water Electrolysis: A Review

Proton exchange membrane water electrolysis (PEMWE) represents promising technology for the generation of high-purity hydrogen using electricity generated from renewable energy sources (solar and wind). Currently, benchmark catalysts for hydrogen evolution reactions in PEMWE are highly dispersed carbon-supported Pt-based materials. In order for this technology to be used on a large scale and be market competitive, it is highly desirable to better understand its performance and reduce the production costs associated with the use of expensive noble metal cathodes. The development of non-noble metal cathodes poses a major challenge for scientists, as their electrocatalytic activity still does not exceed the performance of the benchmark carbon-supported Pt. Therefore, many published works deal with the use of platinum group materials, but in reduced quantities (below 0.5 mg cm-2). These Pd-, Ru-, and Rh-based electrodes are highly efficient in hydrogen production and have the potential for large-scale application. Nevertheless, great progress is needed in the field of water electrolysis to improve the activity and stability of the developed catalysts, especially in the context of industrial applications. Therefore, the aim of this review is to present all the process features related to the hydrogen evolution mechanism in water electrolysis, with a focus on PEMWE, and to provide an outlook on recently developed novel electrocatalysts that could be used as cathode materials in PEMWE in the future. Non-noble metal options consisting of transition metal sulfides, phosphides, and carbides, as well as alternatives with reduced noble metals content, will be presented in detail. In addition, the paper provides a brief overview of the application of PEMWE systems at the European level and related initiatives that promote green hydrogen production.

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.

Corrosion Resistance of AISI 442 and AISI 446 Ferritic Stainless Steels as a Support for PEMWE Bipolar Plates

Cost reduction in bipolar plates in proton exchange membrane water electrolyzers has previously been attempted by substituting bulk titanium with austenitic stainless steels protected with highly conductive and corrosion-resistant coatings. However, austenitic steels are more expensive than ferritic steels due to their high nickel content. Herein we report on the corrosion resistance of two high chromium ferritic stainless steels, AISI 442 and AISI 446, as an alternative material to manufacture bipolar plates. Electrochemical corrosion tests have shown that AISI 442 and AISI 446 have similar corrosion resistance, while AISI 446 reveals more noble corrosion potential and performs better during potentiostatic stress tests. The current density obtained during polarization at 2 V versus the standard hydrogen electrode (SHE) is 3.3 mA cm^-2, which is more than two times lower than on AISI 442. Additionally, surface morphology characterization demonstrates that in contrast to AISI 442, AISI 446 is not sensitive to intercrystalline or pitting corrosion. Moreover, EDX energy dispersion analysis of AISI 446 reveals no differences in the chemical composition of the surface layer compared to the base material, as a confirmation of its high corrosion resistance. The results of this work open up the perspective of replacing austenitic stainless steels with less expensive ferritic stainless steels for the production of components such as bipolar plates in proton exchange membrane water electrolyzers.

N+-Implantation on Nb Coating as Protective Layer for Metal Bipolar Plate in PEMFCs and Their Electrochemical Characteristics

Nitrogen ions were implanted into the coated Nb layer by plasma immersion ion implantation to improve resistance to corrosion of a metal bipolar plate. Due to nitrogen implantation, the corrosion behavior of the Nb layer was enhanced. The electron microscope observation reveals that the microstructure of the Nb layer became denser and had fewer defects with increasing implantation energy. As a result, the densified structure effectively prevented direct contact with the corrosive electrolyte. In addition, at a higher implantation rate (6.40 × 1017 N2/cm2), a thin amorphous layer was formed on the surface, and the implanted nitrogen ions reacted at neighboring Nb sites, resulting in the localized formation of nitrides. Such phase and structural changes contributed to further improve corrosion resistance. In particular, the implanted Nb layer at bias voltage of 10 kV exhibited a current density more than one order of magnitude smaller with a two times faster stabilization than the as-deposited Nb layer under the PEMFC operating conditions.

A Holistic Consideration of Megawatt Electrolysis as a Key Component of Sector Coupling

In the future, hydrogen (H2) will play a significant role in the sustainable supply of energy and raw materials to various sectors. Therefore, the electrolysis of water required for industrial-scale H2 production represents a key component in the generation of renewable electricity. Within the scope of fundamental research work on cell components for polymer electrolyte membrane (PEM) electrolyzers and application-oriented living labs, an MW electrolysis system was used to further improve industrial-scale electrolysis technology in terms of its basic structure and systems-related integration. The planning of this work, as well as the analytical and technical approaches taken, along with the essential results of research and development are presented herein. The focus of this study is the test facility for a megawatt PEM electrolysis stack with the presentation of the design, processing, and assembly of the main components of the facility and stack.

Towards Replacing Titanium with Copper in the Bipolar Plates for Proton Exchange Membrane Water Electrolysis

For proton exchange membrane water electrolysis (PEMWE) to become competitive, the cost of stack components, such as bipolar plates (BPP), needs to be reduced. This can be achieved by using coated low-cost materials, such as copper as alternative to titanium. Herein we report on highly corrosion-resistant copper BPP coated with niobium. All investigated samples showed excellent corrosion resistance properties, with corrosion currents lower than 0.1 µA cm⁻² in a simulated PEM electrolyzer environment at two different pH values. The physico-chemical properties of the Nb coatings are thoroughly characterized by scanning electron microscopy (SEM), electrochemical impedance spectroscopy (EIS), X-ray photoelectron spectroscopy (XPS), and atomic force microscopy (AFM). A 30 µm thick Nb coating fully protects the Cu against corrosion due to the formation of a passive oxide layer on its surface, predominantly composed of Nb₂O₅. The thickness of the passive oxide layer determined by both EIS and XPS is in the range of 10 nm. The results reported here demonstrate the effectiveness of Nb for protecting Cu against corrosion, opening the possibility to use it for the manufacturing of BPP for PEMWE. The latter was confirmed by its successful implementation in a single cell PEMWE based on hydraulic compression technology.

Low-Cost Bipolar Plates of Ti4O7-Coated Ti for Water Electrolysis with Polymer Electrolyte Membranes

Although hydrogen is expected to play an important role in the storage of energy from renewable energy sources, technology to produce hydrogen at low cost is needed for its widespread use. The key to the low-cost production of hydrogen with a polymer electrolyte membrane (PEM) water electrolysis system, which is widely used today, is to replace the Au- or Pt-coated Ti with a low-cost material that can be manufactured from inexpensive, corrosion-resistant, and conductive components. We studied titanium suboxide (Ti₄O₇)-coated titanium (Ti) bipolar plates, which can be substituted for commonly used Pt-coated Ti bipolar plates, as an inexpensive way of producing the PEM water electrolysis system. The water electrolysis characteristics of the cell were evaluated using Ti₄O₇-sputtered Ti for the bipolar plates of the water electrolysis cell, and the applicability of Ti₄O₇-sputtered Ti was investigated. The Ti₄O₇-sputtered Ti had a very low contact resistance (4-5 mΩ cm²) before and after voltage application that was equivalent to that of gold or platinum plating. The efficiency of water electrolysis in this study was comparable to those of previous reports using bipolar plates coated with precious metals. This development opens the door for fabrication of low-cost electrolyzers as well as related electrochemical devices such as fuel cells, sensors, catalysts, and air or liquid cleaning devices.

Reconciling temperature-dependent factors affecting mass transport losses in polymer electrolyte membrane electrolyzers

In this work, we investigated the impact of temperature on two-phase transport in low temperature (LT)-polymer electrolyte membrane (PEM) electrolyzer anode flow channels via in operando neutron imaging and observed a decrease in mass transport overpotential with increasing temperature. We observed an increase in anode oxygen gas content with increasing temperature, which was counter-intu.itive to the trends in mass transport overpotential. We attributed this counterintuitive decrease in mass transport overpotential to the enhanced reactant distribution in the flow channels as a result of the temperature increase, determined via a one-dimensional analytical model. We further determined that gas accumulation and fluid property changes are competing, temperature-dependent contributors to mass transport overpotential; however, liquid water viscosity changes led to the dominate enhancement of reactant water distributions in the anode. We present this temperature-dependent mass transport overpotential as a great opportunity for further increasing the voltage efficiency of PEM electrolyzers.

Impact of Film Thickness on Defects and the Graphitization of Nanothin Carbon Coatings Used for Metallic Bipolar Plates in Proton Exchange Membrane Fuel Cells

Metallic bipolar plates (BPPs) are considered promising alternatives to traditional graphite BPPs used in proton exchange membrane fuel cells (PEMFCs). Major auto companies, such as Toyota, GM, Ford, and BMW, are focusing on the development of metallic BPPs. Amorphous carbon (a-C) coating are widely known to be effective at enhancing the performance of metallic BPPs. However, a-C coatings prepared by sputtering are mostly micrometers thick, which can render mass production difficult due to their low deposition rates. In this study, we investigate effects of thickness on the formation of defects and the graphitization of nanothin a-C layers deposited by magnetron sputtering from scanning electron microscope (SEM) and transmission electron microscope (TEM) observations, internal stress measurements, X-ray diffractometer (XRD) data, Raman spectra, and X-ray photoelectron spectroscopy (XPS). Furthermore, corrosion and interfacial contact resistance (ICR) test results show that an approximately 69 nm a-C layer, with a deposition time of only 15 min, can meet ex situ technical targets of US Department of Energy. As the thickness of a-C layers increases, vacancy-like defects become more pronounced, which is accompanied by stress relaxation. Furthermore, the larger the graphite-like clusters, the more sp²-hybridization carbon atoms found in loose a-C films. The good properties of nanothin a-C layers are attributed to their limited defects and proper graphitization.