Linking structure to performance: Characterization of porous transport layers for high-pressure water electrolysis

Duarte, Ricardo P.M.; Kowal, Andrea; Young, James; Lang, Jack Todd; Zenyuk, Iryna; Wrubel, Jacob A.; Bender, Guido

doi:10.1016/j.ijhydene.2025.150924

Linking structure to performance: Characterization of porous transport layers for high-pressure water electrolysis

Journal Article · Thu Aug 14 00:00:00 EDT 2025 · International Journal of Hydrogen Energy

DOI:https://doi.org/10.1016/j.ijhydene.2025.150924· OSTI ID:2587212

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National Renewable Energy Laboratory (NREL), Golden, CO (United States)
University of California, Irvine, CA (United States)

Proton exchange membrane (PEM) water electrolysis is a promising technology to produce cost-efficient hydrogen. PEM electrolyzers offer a large current density range and the ability to operate at differential pressure which can be used to minimize both capital and operational expenditures. However, directly producing pressurized hydrogen at the cathode results in pushing the membrane against the anode porous transport layer (PTL). This can lead to detrimental effects, such as membrane deformation or ruptures, which depend on membrane properties as well as PTL material properties such as pore size, structure, and morphology. In this work, a range of sinter and felt-based commercial PTLs are evaluated for their contributions to the cell's electrochemical and H₂ crossover performance at cathode pressures up to 30 bar. X-ray tomography and post-operando optical microscopy are used to assess the morphology of the PTLs, and the PTL induced deformation experienced by the catalyst coated membrane (CCM), respectively. PTL samples with lower porosity were found to reduce both the cell voltage and the amount of H₂ permeating from the cathode to the anode exhaust, which was ascribed to improved catalyst layer contact and reduced membrane deformation, respectively. The best performing PTLs improved electrolyzer efficiency by ~1.5 kWh/kg_H2. Specifically, 1 kWh/kg_H2 was gained due to reducing membrane deformation and decreasing H₂ crossover. The remainder 0.5 kWh/kg_H2 were achieved by improving the electrical contact at the electrode/PTL interface which decreased cell voltage.

View Accepted Manuscript (DOE)

Research Organization:: National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Hydrogen Fuel Cell Technologies Office (HFTO)

Grant/Contract Number:: AC36-08GO28308

OSTI ID:: 2587212

Report Number(s):: NREL/JA--5900-93608

Journal Information:: International Journal of Hydrogen Energy, Journal Name: International Journal of Hydrogen Energy Vol. 165; ISSN 0360-3199

Publisher:: Elsevier BVCopyright Statement

Country of Publication:: United States

Language:: English

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