Experimental characterization and non-isothermal simulation of a zero-gap alkaline electrolyser with nickel-iron porous electrode

The availability of self-supported porous electrodes with excellent hydrogen evolution reaction (HER) and oxygen evolution reaction (OER) catalytic activity has been an important cornerstone for the performance of alkaline water electrolysers (AWEs). In addition, the management of heat and two-phase flow during ion/electron transfer in porous electrodes poses significant challenges to the stable operation of AWE electrolysers. In this work, a two-dimensional non-isothermal multiphysical model considering two-phase flow, mass, heat and charge transfer processes is developed based on COMSOL Multiphysics and well validated with reliable experimental data. The model exhibits excellent agreement with actual electrolyser operating voltages between 323–343 K, and the relative error is within acceptable 2.2% even at high current densities up to 1.5 A cm−2. In addition, the electrode kinetic data obtained based on standard three-electrode experiments allow the model to predict the corresponding HER and OER overpotentials of the porous electrodes with great accuracy, as well as to obtain the distribution of temperature and ionic species inside the porous electrodes under various volumetric flow rates and current densities. This work provides a practical and reliable guide for the design of porous electrodes and the performance enhancement of electrolysers from both experimental and simulation perspectives.