Hydrogen crossover in proton exchange membrane electrolysers: The effect of current density, pressure, temperature, and compression

Cathode Catalyst Layer Design in PEM Water Electrolysis toward Reduced Pt Loading and Hydrogen Crossover

Reducing the use of platinum group metals is crucial for the large-scale deployment of proton exchange membrane (PEM) water electrolysis systems. The optimization of the cathode catalyst layer and decrease of the cathode Pt loading are usually overlooked due to the predominant focus of research on the anode. However, given the close relationship between the rate of hydrogen permeation through the membrane in an operating cell and the local hydrogen concentration near the membrane-cathode interface, the structural design of the cathode catalyst layer is considered to be of pivotal importance for reducing H2 crossover, particularly in combination with the use of thin (≲50 μm) membranes. In this study, we have conducted a detailed investigation on the cathode structural parameters, covering the Pt wt % of the Pt/C electrocatalyst, the type of carbon support (Vulcan and high surface area carbon, HSAC), and the ionomer content, with a goal to reduce Pt loading to 0.025 mgPt/cm2 while minimizing the rate of cell hydrogen crossover. We found that the electrochemical performance is mainly influenced by the changes in the interfacial contact resistance due to variations in the cathode thickness. Both the Pt wt % in Pt/C and the ionomer content showed a positive correlation with the measured H2 in O2% in the anode outlet, whereas the Pt loading exhibited an opposite trend. The rate of hydrogen crossover was analyzed in relation to the calculated local volumetric current density within the cathode catalyst layer. Based on the obtained hydrogen mass transfer coefficient, a cathode catalyst layer comprising 40 wt % Pt on HSAC support with an ionomer-to-carbon (I/C) ratio of 0.35 was found to be an optimum configuration for achieving a low Pt loading of 0.025 mgPt/cm2 and a reduced rate of hydrogen crossover.

Ce-radical Scavenger-Based Perfluorosulfonic Acid Aquivion® Membrane for Pressurised PEM Electrolysers

A Ce-radical scavenger-based perfluorosulfonic acid (PFSA) Aquivion® membrane (C98 05S-RSP) was developed and assessed for polymer electrolyte membrane (PEM) electrolyser applications. The membrane, produced by Solvay Specialty Polymers, had an equivalent weight (EW) of 980 g/eq and a thickness of 50 μm to reduce ohmic losses at a high current density. The electrochemical properties and gas crossover through the membrane were evaluated upon the formation of a membrane-electrode assembly (MEA) in a range of temperatures between 30 and 90 °C and at various differential pressures (ambient, 10 and 20 bars). Bare extruded (E98 05S) and reinforced (R98 05S) PFSA Aquivion® membranes with similar EWs and thicknesses were assessed for comparison in terms of their performance, stability and hydrogen crossover under the same operating conditions. The method used for the membrane manufacturing significantly influenced the interfacial properties, with the electrodes affecting the polarisation resistance and H2 permeation in the oxygen stream, as well as the degradation rate, as observed in the durability studies.

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.

Analysis of PEM Water Electrolyzer Failure Due to Induced Hydrogen Crossover in Catalyst-Coated PFSA Membranes

Polymer electrolyte membrane water electrolysis (PEMWE) is a leading candidate for the development of a sustainable hydrogen infrastructure. The heart of a PEMWE cell is represented by the membrane electrode assembly (MEA), which consists of a polymer electrolyte membrane (PEM) with catalyst layers (CLs), flow fields, and bipolar plates (BPPs). The weakest component of the system is the PEM, as it is prone to chemical and mechanical degradation. Membrane chemical degradation is associated with the formation of hydrogen peroxide due to the crossover of product gases (H₂ and O₂). In this paper, membrane failure due to H₂ crossover was addressed in a membrane-focused accelerated stress test (AST). Asymmetric H₂O and gas supply were applied to a test cell in OCV mode at two temperatures (60 °C and 80 °C). Electrochemical characterization at the beginning and at the end of testing revealed a 1.6-fold higher increase in the high-frequency resistance (HFR) at 80 °C. The hydrogen crossover was measured with a micro-GC, and the fluoride emission rate (FER) was monitored during the ASTs. A direct correlation between the FER and H₂ crossover was identified, and accelerated membrane degradation at higher temperatures was detected.

Nafion Composite Membranes Impregnated with Polydopamine and Poly(Sulfonated Dopamine) for High-Performance Proton Exchange Membranes

We prepared Nafion composite membranes by impregnating Nafion-212 with polydopamine, poly(sulfonated dopamine), and poly(dopamine-co-sulfonated dopamine) using the swelling-filling method to generate nanopores in the Nafion framework that were filled with these polymers. Compared to the pristine Nafion-212 membrane, these composite membranes showed improved thermal and mechanical stabilities due to the strong interactions between the catecholamine of the polydopamine derivatives and the Nafion matrix. For the composite membrane filled with poly(sulfonated dopamine) (N-PSDA), further interactions were induced between the Nafion and the sulfonic acid side chain, resulting in enhanced water uptake and ion conductivity. In addition, filling the nanopores in the Nafion matrix with polymer fillers containing aromatic hydrocarbon-based dopamine units led to an increase in the degree of crystallinity and resulted in a significant decrease in the hydrogen permeability of the composite membranes compared to Nafion-212. Hydrogen crossovers 26.8% lower than Nafion-212 at 95% relative humidity (RH) (fuel cell operating conditions) and 27.3% lower at 100% RH (water electrolysis operating conditions) were obtained. When applied to proton exchange membrane-based fuel cells, N-PSDA exhibited a peak power density of 966 mW cm^-2, whereas N-PSDA showed a current density of 4785 mA cm^-2, which is 12.4% higher than Nafion-212 at 2.0 V and 80 °C.