Water electrolysis is a crucial technology for large-scale hydrogen generation, that is required for the transition to a fossil fuel-free energy system. Even though water electrolysis systems are already deployed in a limited capacity, the technology is largely constrained to liquid alkaline electrolysis. Proton exchange membrane (PEM) electrolysis could pose an alternative but it is still hindered by high investment costs, in-part due to its reliance on scarce noble-metal catalysts. Alternative structural designs of the anode catalyst layer (CL) could reduce Iridium loading of the whole system and thus accelerate its wide-spread application. In fuel cell research, it was already reported that a multi-layer design with varied ionomer content enhances performance of the CL and in-turn lowers required catalyst loading.[1,2,3]

In this study, a gradient design for ionomer content is employed for anode CLs for the application in PEM water electrolysis. CLs are coated in a stacked multi-layer design via ultrasonic spray coating of Iridium/Nafion^® suspensions. The target ionomer loadings (10 and 30 wt.%) are confirmed by a combination of thermo-gravimetric analysis (TGA) and X-ray photoelectron spectroscopy (XPS). The coating process yields homogenously loaded reference CLs as well as through-plane graded CLs with the desired ionomer loading. Additionally, scanning electron microscopy (SEM) in conjunction with energy dispersive spectroscopy (EDS) shows equal CL thickness across all ionomer loadings and spatially differentiated Nafion^® content throughout the CLs thickness. Electrochemical characterizations are carried out in an electrolysis-adapted gas diffusion electrode (GDE) half-cell setup to allow for quick examination and prototyping of produced layers. Differences in electrochemical performance of these layers can be observed with one gradient design CL showing reduced overpotential across all current densities compared to the homogenous CLs. In-particular a high ionomer loading near the membrane improves performance, most likely due to increased proton conduction to the membrane and higher available pore volume near the porous transport layer.

Further analysis is performed on electrochemical studies to deepen the understanding of the role of ionomer in anodic PEM water electrolysis CLs. Particularly, the investigation of protonic and electric conductivity through the CL is of interest, because this parameter is most influenced by ionomer loading.[4]

References:

[1] Y. Wang, T. Liu, H. Sun, H. Wie, F. Yuanzhi, S. Wang, Electrochimica Acta 2020, 353, 136791.

[2] R. Roshandel, F. Ahmadi, Renewable Energy 2013, 50, 921-931.

[3] K.-H. Kim, H.-J. Kim, K.-Y. Lee, J.H. Jang, S.-Y. Lee, E. Cho, I.H. Oh, T.H. Lim, International Journal of Hydrogen Energy 2008, 33, 2783-2789.

[4] M. Mandal, M. Moore, M. Secanell, ACS Applied Materials & Interfaces 2020, 13, 49549-49562.