Impact of cell design and conditioning on polymer electrolyte membrane water electrolyzer operation

Integration of polymer electrolyte membrane water electrolyzers (PEMWEs) for clean hydrogen generation requires a robust understanding of the impact cell designs and conditioning protocols have on operation and stability. Here, catalyst-coated electrode and catalyst-coated membrane cells employing Pt/C cathode catalyst layer, an IrO2 anode catalyst layer, with a platinized titanium mesh or a carbon paper with a microporous layer as the porous transport layer were developed. The impact of cell conditioning above and below 0.25 A cm−2 was investigated using advanced electrochemical impedance spectroscopy analyses and microscopic imaging, with the electrochemical response related to physicochemical processes. Operation below 0.25 A cm−2 prior to operation above 0.25 A cm−2 resulted in anode corrosion and titanium cation contamination, increasing the cell voltage at 1 A cm−2 by 200 mV compared to uncontaminated cells. Conditioning above 0.25 A cm−2 led to non-negligible hydrogen transport resistances due to cathode flooding that resulted in a ca. 50 mV contribution at 1 A cm−2 and convoluted with the anode impedance response. The presence of a microporous layer increased catalyst utilization but increased the cell voltage by 300 mV at 1 A cm−2 due to increased anodic mass transport resistances. These results yield critical insights into the impact of PEMWE cell design and operation on corresponding cell performance and stability while highlighting the need for application dependent standardized operating protocols and operational windows. © 2024