Durability Assessment of Roll-to-Roll Coated PEM Water Electrolysis Anodes

Abstract

Widespread adoption of green hydrogen relies on the high-throughput production of key electrolyzer components in a manner yielding acceptable stack manufacturing costs. Roll-to-roll liquid coating methods, such as slot die and gravure coating, are particularly relevant means to produce key components (e.g., membranes and electrodes) at high throughput. In the case of proton exchange membrane water electrolysis (PEMWE), thrifting of expensive iridium-based catalysts poses additional challenges to the implementation of such high-throughput coating methods for iridium-based anode manufacture.Herein, we investigate key challenges around roll-to-roll manufacture of low-loaded (<0.2 mgIr/cm2) iridium-based electrodes for PEMWE. In particular, we highlight fundamental limitations in coating the thin layers required to manufacture low-loaded electrodes, for which the improper choice of coating conditions may lead to macro- and micro-scale heterogeneity. By addressing causes of this heterogeneity, homogeneous slot-die coated iridium oxide anodes of varying iridium loading are produced on decal substrates. Catalyst coated membranes (CCMs) are subsequently produced from these anodes via hot-pressed decal transfer, and 1,000 hour constant current tests are conducted with intermediate diagnostics (polarization curves and impedance spectroscopy). Key effects of loading and homogeneity on electrode durability are highlighted, and future directions are discussed.This work was authored by the National Renewable Energy Laboratory, operated by Alliance for Sustainable Energy, LLC, for the U.S. Department of Energy (DOE) under Contract No. DE-AC36-08GO28308. Funding provided by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Hydrogen and Fuel Cell Technologies Office and Advanced Manufacturing Office. The views expressed in the article do not necessarily represent the views of the DOE or the U.S. Government. The U.S. Government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for U.S. Government purposes.