The growing demand for efficient, cost-effective and sustainable energy systems has prompted significant research into the development of advanced electrochemical devices. Hybrid battery electrolyzer, integrating the capabilities of both battery and electrolyzer, is a groundbreaking technology aiming to enhance both energy conversion efficiency and storage capacity. [1] Iron with large earth-abundance, low-cost, robustness, and high capacity is a promising electrode material for such hybrid energy systems. [2-4]This study focuses on the design, fabrication, and performance evaluation of a novel porous iron electrode tailored for use in a hybrid battery electrolyzer system. The proposed electrode exhibits superior electrocatalytic activity, enhanced mass transport properties, and increased surface area, contributing to improved overall performance. The electrode's porosity and pore structure are tuned to facilitate efficient mass transport and electrolyte penetration, addressing common challenges associated with conventional electrodes. The electrochemical performance of the optimised porosity iron electrode is investigated through comprehensive characterization techniques, including scanning electron microscopy (SEM), X-ray diffraction (XRD), electrochemical impedance spectroscopy (EIS), cyclic voltammetry (CV), and charge-discharge cycling tests. Results indicate superior electrochemical properties, showcasing enhanced specific capacity, faster charge/discharge kinetics, and prolonged cycle life compared to conventional electrodes. The incorporation of conducting nanocarbon and sintering at optimized temperature of 800 ℃ led to the achievement of a stable and elevated capacity exceeding 500 mAh/g for these advanced iron electrodes. The iron electrodes exhibit outstanding porosity (65 - 70%), along with a pore size of 5-10 µm. This configuration results in exceptional current rate performance, achieving a discharge capacity of 350 mAh/cm2 at a current density of 35 mA/cm2 and 245 mAh/cm2 at 50 mA/cm2. Furthermore, the iron electrodes exhibit superior performance in high-current electrolysis, showcasing an HER potential of -1.25, -1.34, and -1.50 V (vs Hg/HgO) at a current density of 200, 500 and 1000 mA/cm2 respectively.These findings highlight the potential of optimised porosity iron electrodes as a key component in the development of high-performance and cost-effective hybrid battery electrolyzer systems. The integration of such advanced materials holds promise for unlocking new frontiers in energy storage and green hydrogen technology, contributing to the realization of efficient and sustainable energy systems.
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