3D Multilayered DDM-Modified Nickel Foam Electrode for Advanced Alkaline Water Electrolysis

Area of Science:

• Electrochemistry
• Materials Science
• Sustainable Energy

Background:

• Advanced alkaline water electrolysis (AWE) is crucial for low-temperature hydrogen production.
• Nickel-based electrodes are key to AWE efficiency, particularly in zero-gap configurations.
• Electrode design and surface chemistry significantly impact AWE performance.

Purpose of the Study:

• To develop a simple and low-cost method for modifying commercial nickel foam electrodes.
• To evaluate the electrochemical performance of modified electrodes in alkaline media and a zero-gap cell.
• To investigate the impact of a Ni-FeOOH/PTFE catalytic layer on AWE efficiency and gas release.

Main Methods:

• A dip-and-drying method (DDM) was used to apply a Ni-FeOOH/PTFE microporous catalytic layer onto nickel foam.
• Electrochemical performance was tested in 1 M KOH and a laboratory zero-gap cell with a Zirfon® Perl 500 UTP diaphragm using 25 wt.% KOH.
• The modified electrodes (DDM-NF-CAT-A) were characterized after annealing.

Main Results:

• The FeSO4-assisted DDM treatment created mixed Ni-Fe oxyhydroxide species with controlled hydrophobicity from PTFE.
• Annealed electrodes achieved a cell voltage of 2.45 V at 1 A·cm⁻² and 80 °C in the zero-gap cell.
• The method demonstrated moderate performance, comparable to other low-complexity Ni-based electrodes, with stable short-term (80 h) operation.

Conclusions:

• The dip-and-drying method offers a simple, cost-effective route for producing structured nickel foam electrodes for AWE.
• The modified electrodes show promise for enhancing catalytic activity and gas release in alkaline water electrolysis.
• Further optimization of catalyst loading, microstructure, and long-term stability is recommended for industrial AWE applications.