High Efficiency PEM Water Electrolysis Enabled By Advanced Catalysts, Membranes and Processes

Commercial water electrolysis technologies, including proton exchange membrane electrolysis (PEMWE), are the only renewable hydrogen generation technologies that can achieve the U.S. Department of Energy (DOE) cost targets within the next ten years at the required scale, based on the supply chain maturity and materials performance. In particular, membrane and electrode modifications have enabled the use of advanced electrolysis membranes to achieve the efficiency targets, while nanoengineered alloy catalyst layers (CLs) have been pursued to meet the cost and efficiency targets. These advancements have been achieved by building the basic understanding to allow the successful technical development and include: (1) Mechanical and chemical understanding of membranes in liquid water below 90oC; (2) Characterization of as-deposited electrodes and MEAs after operation; (3) Water management in the anode catalyst layer, dependence on catalyst loading and porous transport layer form factor; and (4) Long-term degradation rate and stability of engineered alloy Ru-Ir alloy nanocatalysts in well-defined anode catalyst layers. Nel Hydrogen’s pathway to meet these DOE goals is through the i) use of 50-75% thinner membranes that operate at 80-90 oC, while controlling mechanical creep and gas crossover; ii) reducing the catalyst loading to 1/10th the current value on both electrodes, while controlling water distribution and the porous transport layer/catalyst layer (PTL/CL) electrochemical interface; iii) incorporation of a less stable but more active Ru containing catalyst managed on the anode side of the cell, which is achievable with lower voltage operation (accomplished via low ohmic drop in the anode catalyst layer, thinner membranes, and higher temperature operation); and iv) fabricating a membrane electrode assembly (MEA) integrating all of these characteristics. In this talk, some of the advancements achieved and how these have impacted the cost of hydrogen will be discussed, as well as the longer-term targets that need to be reached to provide the robustness required for commercial applications. Additionally, cost models will be compared along with sensitivity analysis to show how the impact of operating parameters, with regard to the capital and operational expense for the PEM electrolysis technology cost, show the critical areas to focus on to provide the largest impact towards meeting cost target goals and what is required to go beyond. Figure 1