Optimization of Transport Components and Electrode Interfaces for Low Iridium Oxide Loading PEM Electrolysis

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Moving towards lower iridium oxide (IrOx) catalyst loadings for the anode side of polymer electrolyte membrane water electrolyzers (PEMWE) requires tuning of the catalyst layer-porous transport layer (PTL) interface. To see widespread deployment, PEMWE anodes need to lower the loadings from 1-2 mg/cm2 IrOx down to 0.1 mg/cm2 [1]. The catalyst layer can become less uniform and more disconnected at these lower loadings, so the addition and optimization of a microporous layer (MPL) onto the PTL to improve interfacial contact and in-plane connectivity is essential to move toward the more sustainable lower loadings [2]. First, a set of PTLs with MPLs are made such that morphological properties are varied between them. Then, the PTLs with MPLs are combined with anode catalyst layers with IrOx loadings of 0.7, 0.5, 0.3, and 0.1 mg/cm2 to create cells to record polarization curves, stability tests, and catalyst degradation rates. The morphology of the PTLs and MPLs is quantified using X-ray computed tomography (CT). The important morphological characteristics that can be varied and measured with X-ray CT include porosity, pore size distribution, tortuosity, and thickness for each the MPL and base PTL. Using operando X-ray CT and radiography, oxygen transport through the PTL and channel can be observed to provide further information to the performance of the novel PTLs and MPLs. By using a two-dimensional continuum PEMWE model, insights into the effects on the cell performance and the contact resistance present at the MPL-catalyst layer brought about from PTL and MPL morphology alterations can be extracted to help guide the optimization efforts. Through combining these results, an optimal set of manufacturing/morphological parameters can be found to tune PTL and MPL production for the low-loaded catalyst layers that are needed for the future of PEMWEs. References: [1] M. Clapp, C. M. Zalitis, and M. Ryan, “Perspectives on current and future iridium demand and iridium oxide catalysts for PEM water electrolysis,” Catalysis Today, vol. 420, p. 114140, 2023. doi:10.1016/j.cattod.2023.114140 [2] M. Bernt, A. Siebel, and H. A. Gasteiger, “Analysis of voltage losses in PEM water electrolyzers with low platinum group metal loadings,” Journal of The Electrochemical Society, vol. 165, no. 5, 2018. doi:10.1149/2.0641805jes

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