Catalyst Application in Three-Dimensional Porous Electrodes for Alkaline Electrolysis

Abstract

Hydrogen is critical in the green transition, and a key system for producing green hydrogen is through alkaline electrolysis. Although the alkaline electrolyzers are mature and commercially available, vast improvements are still expected in the future 1.Traditional and most commercially applied alkaline electrolyzer electrodes are made from massive nickel plates (or nickel-plated steel plates) with some scattered perforation. With the ongoing development of thin alkaline ion‐conducting membranes with low internal resistance, the benefit of three‐dimensional porous electrodes becomes obvious. With such electrodes, there will be no blind spots and the active catalytic area can be increased significantly. Today, most groups developing such 3D electrodes use commercial nickel foam as substrate. This limits the options to what is available in the market, moreover the purchase cost is high.The present work aims at developing high‐performing three‐dimensional hydrogen and oxygen evolution electrodes for alkaline electrolysis. The focus will be on the application of nanostructured electrocatalysts into three‐dimensional electrode structures, similar to nickel foams.The results obtained, so far, show homogeneous formation of nanoparticles on the surface. The analysed samples show mechanical flexibility as soon as the particles are deposited but samples become rigid after testing in a half cell setup with KOH 1 M electrolyte. Further analysis will explore changes to the microstructure. The roughness factor calculated by non-faradaic cyclic voltammetry is in the range of 75 cm2 ECSA / cm2geometric, showing higher value than the commercial Nickel foam.Initial experiments are carried out on as-prepared samples, but more advanced catalysts are also explored based on state-of-the-art materials. [1] IRENA - Green Hydrogen Cost Reduction: Scaling up Electrolysers to Meet the 1.5 °C Climate Goal, International Renewable Energy Agency, Abu Dhabi (2020)