Sustainable catalyst-coated electrodes for efficient AEM electrolyser production (SAEP)

Hydrogen is key to a sustainable energy economy, yet its production remains largely carbon-intensive, with only a small fraction generated via electrolysis. Advancing competent and cost-effective electrolysis technologies is crucial for carbon-neutral hydrogen production. AEMWE technology (Anion Exchange Membrane Water Electrolysis) offers a promising alternative by combining the benefits of existing methods but faces challenges like low current densities and electrode degradation. The SAEP project focuses on the core approach to AEMWE development by advancing the PGM-free electrocatalyst and electrode design, developing electrode manufacturing process for improving durability, efficiency, and scalability.

Contents and goals

• Development of sustainable catalyst-coated substrate for AEM water electrolyser electrodes that will achieve a high current density and low degradation rate.
• Developing catalyst layers using abundant elements modulated with functional and protective coatings to compensate for performance and longevity by replacing precious PGM catalysts.
• The pre-treatment of the PTL (Porous Transport Layer) to improve the catalyst layer adhesion and corrosion resistance of electrodes.
• Achieving economy of scale to reduce the production cost of the electrodes produced with roll-to-roll manufacturing, thus enabling wider adoption of AEMWE technology.

Methodological approach

"SAEP" project plans will follow innovative measures at multiple stages of electrode production:

• PTL selection will ensure robustness, recyclability, and rollability for a high throughput production with a roll-to-roll coater and lower the costs and the environmental impact of electrolyser manufacturing.
• Surface pre-treatment of the PTL to enhance its wettability and surface functionalization for better adhesion of catalyst will be explored.
• Investigating and tuning the catalyst properties for reinforcing and stabilizing the catalyst layer on the electrodes.
• The formation of a protective, corrosion-resistant surface coating on the electrode helps to prevent the oxidative leaching of catalytically active centers and addresses the challenge of increasing efficiency by boosting catalyst activity.
• Drying conditions are optimized to monitor the microstructure influenced by viscosity and particle flow, thus ensuring an even distribution of the catalyst.
• Roll-to-roll (R2R) coating manufacturing of electrodes enables efficient scaling of production by increasing output without a proportional rise in costs. This process will lower the cost per electrode through bulk purchasing and more effective resource utilization.
• Life Cycle Assessment (LCA) performed for the sustainability practices implemented in the SAEP project during the CCS fabrication process will facilitate the selection of materials and processes that align with sustainability goals, specifically reducing carbon emissions and minimizing waste.

Expected results

Significant improvement in the performance and efficiency of the AEMWE will be achieved by fine-tuning the electrodes, and by developing the catalyst layers and PTLs in the project.

By integrating circular economy principles, SAEP contributes to making AEMWE more sustainable, economically viable, and adaptable for future hydrogen needs.

Projektleitung

Prof. Viktor Hacker
Technische Universität Graz Institut für Chemische Verfahrenstechnik und Umwelttechnik

Projektpartner

• JOANNEUM RESEARCH Forschungsgesellschaft mbH
• Duramea FlexCo

Prof. Viktor Hacker
Graz University of Technology Institute of Chemical Engineering and Environmental Technology
Inffeldgasse 25 C, 8010 Graz
Tel.: +43 316 873 - 8780
E-Mail: viktor.hacker@tugraz.at
Web: www.ceet.tugraz.at