Effect of Catalyst and Electrode Structures on the Operating Current Densities of Liquid Alkaline Water Electrolyzers

Liquid Alkaline Water Electrolyzers (LAWEs) stand out as the technology best-suited for cost-effective hydrogen production. They do not require expensive platinum group metal catalysts and have proven durability afforded by nickel-based electrodes and porous separators. While nickel electrodes and porous separators provide chemical stability in highly alkaline conditions, they do suffer from lower catalytic activity for hydrogen and oxygen evolution reactions (HER and OER), and separators possess higher ohmic resistance due to the absence of ion-conducting groups. Consequently, most LAWEs operate at low current densities ranging from 0.2 to 0.6 A/cm 2 , resulting in a bulky footprint and comparatively lower energy efficiency due to a reduced hydrogen production rate. To address these challenges, considerable efforts have been directed towards developing thin separators and efficient transition metal-based electrocatalysts for HER and OER in alkaline media. However, the majority of studies related to catalysts are limited to half cells, with only a limited number of catalysts evaluated in relevant LAWE configurations. In this work, we introduce a next-generation Zero-gap LAWE testing capability, benchmarked for performance through H2NEW consortia. Employing this setup, we have evaluated hydrogen and oxygen evolution catalysts under LAWE-relevant conditions on different electrode substrates, each offering a unique electrode structure. Our preliminary findings indicate that Zero-gap LAWEs, when coupled with NiMo cathode and NiFe-type anode catalysts, can operate at current densities exceeding 0.75 A/cm 2 at approximately 1.8 V without compromising their short-term durability. In contrast, the benchmark cell exhibited a meager current density of around 0.22 A/cm 2 . In this presentation, effects of electrode structure, catalyst type, and other relevant parameters related to Zero-gap LAWEs will be discussed in detail. Acknowledgement : This research is supported by the U.S. Department of Energy (DOE) Hydrogen and Fuel Cell Technologies Office through the Hydrogen from Next-generation Electrolyzers of Water (H2NEW) consortium.