Anion-exchange-membrane electrolysis is positioned to play a key role in the predicted exponential growth of green hydrogen technology with essential R&D advances. We reveal key design parameters essential to commercialization. First, stable alkaline oxygen-evolution reaction catalysts with high electronic conductivity and minimal surface reconstruction during operation must be designed. Alkaline catalyst layers must also be applied to the membrane electrode assembly with scalable, industrially relevant techniques. Second, ionomer oxidation mitigation strategies must be developed. This approach could also target other creative catalyst layer design, such as phase-separation control to protect oxidation-prone organic components or catalyst engineering to direct selectivity for hydroxide over polymer oxidation. If competitive efficiency and durability can be achieved in pure water, AEM electrolysis has the potential to become a dominant electrolyzer technology.

Post-operation component disassembly and observation of electrolyzer parts is useful in understanding the interactions of the components and the electrochemical environment beyond the systems electrochemical output. We report a standard protocol for post-operation component disassembly and observation, including directions for cell-component preservation, preliminary visual inspection of cell components, and a guide for the advanced inspection of specific components with suggestions for further analysis if necessary. The procedures outlined here allow for a standardized method that can be used and compared between different laboratories and for literature comparison to experimental results.

Hydroxide-exchange membrane (HEM) electrolyzers can produce green H2 with only earth-abundant catalysts and electrolyte-free (nominally pure) water feed, significantly decreasing system cost and complexity. However, HEM technology suffers from short lifetimes, attributed in part to poor stability of anion-exchange polymers used in the membrane and catalyst layers. We use electrochemical analysis and ex situ characterization techniques to study anion-exchange-polymer degradation in electrolyzers. Using multiple ionomers, catalyst-layer additives, and electrolyte feed, we show how anode-ionomer oxidation is the dominant degradation mechanism for all HEM-based electrolyzer cells tested. We find improved device stability using oxidation-resistant catalyst-layer binders and propose new design strategies for advanced ionomer and catalyst-layer development.

Renewable energy-driven bipolar membrane water electrolyzers (BPMWEs) are a promising technology for sustainable production of hydrogen from seawater and other impure water sources. Here, we present a protocol for assembling BPMWEs and operating them in a range of water feedstocks, including ultra-pure deionized water and seawater. We describe steps for membrane electrode assembly preparation, electrolyzer assembly, and electrochemical evaluation. For complete details on the use and execution of this protocol, please refer to Marin et al. (2023).1.

Among existing water electrolysis (WE) technologies, anion-exchange-membrane water electrolyzers (AEMWEs) show promise for low-cost operation enabled by the basic solid-polymer electrolyte used to conduct hydroxide ions. The basic environment within the electrolyzer, in principle, allows the use of non-platinum-group metal catalysts and less-expensive cell components compared to acidic-membrane systems. Nevertheless, AEMWEs are still underdeveloped, and the degradation and failure modes are not well understood. To improve performance and durability, supporting electrolytes such as KOH and K₂CO₃ are often added to the water feed. The effect of the anion interactions with the ionomer membrane (particularly other than OH^-), however, remains poorly understood. We studied three commercial anion-exchange ionomers (Aemion, Sustainion, and PiperION) during oxygen evolution (OER) at oxidizing potentials in several supporting electrolytes and characterized their chemical stability with surface-sensitive techniques. We analyzed factors including the ionomer conductivity, redox potential, and pH tolerance to determine what governs ionomer stability during OER. Specifically, we discovered that the oxidation of Aemion at the electrode surface is favored in the presence of CO₃^2-/HCO₃^- anions perhaps due to the poor conductivity of that ionomer in the carbonate/bicarbonate form. Sustainion tends to lose its charge-carrying groups as a result of electrochemical degradation favored in basic electrolytes. PiperION seems to be similarly negatively affected by a pH drop and low carbonate/bicarbonate conductivity under the applied oxidizing potential. The insight into the interactions of the supporting electrolyte anions with the ionomer/membrane helps shed light on some of the degradation pathways possible inside of the AEMWE and enables the informed design of materials for water electrolysis.

Proton-exchange-membrane water electrolyzers (PEMWEs) produce high-purity H2, withstand load fluctuations, and operate with a pure-water feed but require platinum-group-metal catalysts for durability, such as IrO2 and Pt, due to the acidic environment. At the anode, the slow oxygen evolution reaction (OER) requires a high overpotential to achieve relevant current densities (>2 A·cm-2) even with a high loading of IrO2. Using a simple commercial 1,5-cyclooctadiene iridium chloride dimer precursor, we synthesized submonolayer-thick IrOx on the surfaces of conductive metal oxides to make every Ir atom available for catalysis and reach the ultimate lower limit for Ir loading. We show that the reaction on Sb/SnO2 and F/SnO2 conductive oxides is surface-limited and that a continuous Ir-O-Ir network provides improved stability and activity. We cover IrOx with a thin layer of acid-stable TiOx by atomic-layer deposition. The effects of TiOx on the catalyst’s performance were assessed by inductively coupled plasma mass spectrometry (ICP-MS) coupled in situ with an electrochemical flow cell and ex situ by X-ray photoelectron spectroscopy. Tuning the binding environment of IrOx by TiOx addition enhances the intrinsic activity of the active sites, simultaneously accelerating the dissolution of the catalyst and the metal-oxide support. We illustrate the interplay between the support, catalyst, and protection-layer dissolution with OER activity, and highlight the effects of annealing to densify the TiOx protection layer on stability/activity. These ultrathin supported Ir-based catalysts do not eliminate the long-standing issue of the catalyst and support instability during OER in acids, but do provide new insight into the catalyst-support interactions and may also be of utility for advanced spectroscopic investigations of the OER mechanism.

Anion-exchange-membrane water electrolyzers (AEMWEs) in principle operate without soluble electrolyte using earth-abundant catalysts and cell materials and thus lower the cost of green H₂ . Current systems lack competitive performance and the durability needed for commercialization. One critical issue is a poor understanding of catalyst-specific degradation processes in the electrolyzer. While non-platinum-group-metal (non-PGM) oxygen-evolution catalysts show excellent performance and durability in strongly alkaline electrolyte, this has not transferred directly to pure-water AEMWEs. Here, AEMWEs with five non-PGM anode catalysts are built and the catalysts' structural stability and interactions with the alkaline ionomer are characterized during electrolyzer operation and post-mortem. The results show catalyst electrical conductivity is one key to obtaining high-performing systems and that many non-PGM catalysts restructure during operation. Dynamic Fe sites correlate with enhanced degradation rates, as does the addition of soluble Fe impurities. In contrast, electronically conductive Co₃ O₄ nanoparticles (without Fe in the crystal structure) yield AEMWEs from simple, standard preparation methods, with performance and stability comparable to IrO₂ . These results reveal the fundamental dynamic catalytic processes resulting in AEMWE device failure under relevant conditions, demonstrate a viable non-PGM catalyst for AEMWE operation, and illustrate underlying design rules for engineering anode catalyst/ionomer layers with higher performance and durability.

Generation of H2 and O2 from untreated water sources represents a promising alternative to ultrapure water required in contemporary proton exchange membrane-based electrolysis. Bipolar membrane-based devices, often used in electrodialysis and CO2 electrolysis, facilitate impure water electrolysis via the simultaneous mediation of ion transport and enforcement of advantageous microenvironments. Herein, we report their application in direct seawater electrolysis; we show that upon introduction of ionic species such as Na+ and Cl− from seawater, bipolar membrane electrolyzers limit the oxidation of Cl− to corrosive OCl− at the anode to a Faradaic efficiency (FE) of 0.005%, while proton exchange membrane electrolyzers under comparable operating conditions exhibit up to 10% FE to Cl− oxidation. The effective mitigation of Cl− oxidation by bipolar membrane electrolyzers underpins their ability to enable longer-term seawater electrolysis than proton exchange membrane assemblies by a factor of 140, suggesting a path to durable seawater electrolysis.