Periodic Reporting for period 1 - 2D4H2 (Anion Exchange Membrane Water stack based on Earth Abundant 2D Materials for Green Hydrogen Production)
Reporting period: 2023-03-01 to 2024-08-31
The baseline technology for green H2 production is water electrolysis (WE). However, roughly 96% of the H2 produced today comes from fossil fuels, with only 4% generated through water electrolysis, primarily due to the high costs and lower performance of current electrolysers compared to other production processes that do not rely on toxic or critical raw materials (CRM). Therefore, there is a need to accelerate the development of highly active and efficient catalysts to make green hydrogen a viable solution for decarbonizing various sectors and achieving the ambitious goals set in the Hydrogen Strategy.
This project proposes an advanced Anion Exchange Membrane Water Electrolyser (AEMWE) stack as a critical milestone in translating the highly promising results from the ground-breaking research conducted during the ERC-StG awarded to Dr. G. Abellán into a marketable innovation. The novelty of the AEMWE stack lies in its non-toxic, CRM-free, breakthrough electrodes (anodes) made of two-dimensional (2D) nickel-iron layered double hydroxide materials (2D NiFe-LDHs), which have demonstrated outstanding catalytic performance. Utilizing this electrocatalytic material will help overcome the main challenges of WE in producing green H2.
The activities under the 2D4H2 project aim to facilitate the transition of 2D NiFe-LDH electrocatalytic materials into an AEMWE stack as a precursor to a future fully operational 0.5 kW electrolyser. This requires the necessary optimization and characterization of the electrocatalyst to enable testing and validation in a pilot plant, both at the single-unit cell level and in an AEMWE stack prototype. Conducting catalyst testing at the single-cell pilot plant level presents multiple challenges that require meticulous optimization and conditioning of various aspects of the experimental setup.
A key factor is maintaining a constant and controlled electrolyte flow within the cell, as variations can significantly impact catalyst performance and activity. Temperature control is equally critical, as catalyst activity is highly sensitive to temperature fluctuations, making a stable operating temperature essential for accurate data collection. Furthermore, ensuring the long-term stability and durability of the pilot cell is paramount. To mitigate corrosion and degradation of cell components, appropriate protective coatings must be optimized and applied. These coatings prevent interactions between the electrolyte and cell materials, preserving structural integrity and functionality over extended operational periods. Optimizing individual cell conditions within a pilot plant not only establishes a foundational framework but also provides valuable insights for scaling up to larger systems, such as cell stacks.
In summary, the objective of this project is to address the challenges of designing pilot-scale AEMWE cells and stacks while incorporating the materials developed through Dr. G. Abellán’s ERC-StG research as catalysts. This initiative aims to advance green hydrogen production, making it a feasible and sustainable reality.
Additionally, the project will be carried out alongside the development of a comprehensive strategy for efficiently managing the knowledge generated. This strategy will include clarifying intellectual property rights (IPR) and formulating an exploitation plan to engage potential stakeholders, thereby bringing the concept closer to practical implementation.
This project proposes an advanced Anion Exchange Membrane Water Electrolyser (AEMWE) stack as a critical milestone in translating the highly promising results from the ground-breaking research conducted during the ERC-StG awarded to Dr. G. Abellán into a marketable innovation. The novelty of the AEMWE stack lies in its non-toxic, CRM-free, breakthrough electrodes (anodes) made of two-dimensional (2D) nickel-iron layered double hydroxide materials (2D NiFe-LDHs), which have demonstrated outstanding catalytic performance. Utilizing this electrocatalytic material will help overcome the main challenges of WE in producing green H2.
The activities under the 2D4H2 project aim to facilitate the transition of 2D NiFe-LDH electrocatalytic materials into an AEMWE stack as a precursor to a future fully operational 0.5 kW electrolyser. This requires the necessary optimization and characterization of the electrocatalyst to enable testing and validation in a pilot plant, both at the single-unit cell level and in an AEMWE stack prototype. Conducting catalyst testing at the single-cell pilot plant level presents multiple challenges that require meticulous optimization and conditioning of various aspects of the experimental setup.
A key factor is maintaining a constant and controlled electrolyte flow within the cell, as variations can significantly impact catalyst performance and activity. Temperature control is equally critical, as catalyst activity is highly sensitive to temperature fluctuations, making a stable operating temperature essential for accurate data collection. Furthermore, ensuring the long-term stability and durability of the pilot cell is paramount. To mitigate corrosion and degradation of cell components, appropriate protective coatings must be optimized and applied. These coatings prevent interactions between the electrolyte and cell materials, preserving structural integrity and functionality over extended operational periods. Optimizing individual cell conditions within a pilot plant not only establishes a foundational framework but also provides valuable insights for scaling up to larger systems, such as cell stacks.
In summary, the objective of this project is to address the challenges of designing pilot-scale AEMWE cells and stacks while incorporating the materials developed through Dr. G. Abellán’s ERC-StG research as catalysts. This initiative aims to advance green hydrogen production, making it a feasible and sustainable reality.
Additionally, the project will be carried out alongside the development of a comprehensive strategy for efficiently managing the knowledge generated. This strategy will include clarifying intellectual property rights (IPR) and formulating an exploitation plan to engage potential stakeholders, thereby bringing the concept closer to practical implementation.
The results obtained thus far in this research project represent a substantial breakthrough aligned with the overarching objective of developing a CRM-free AEMWE (Anion Exchange Membrane Water Electrolysis) system, relying on two-dimensional (2D) nickel-iron layered double hydroxide (LDH) materials. Using a single-cell configuration as a starting point (https://doi.org/10.1039/D3TA02978F) an optimization process was carried out to control critical parameters in an AEMWE stack, such as electrolyte temperature, electrolyte flow, cell temperature, housing and flow field materials, and the electrical isolation of the cathode and anode. This optimization not only enabled a sustained catalytic reaction over time in the single-cell configuration but also unveiled new perspectives and opportunities in the design of advanced cell/stack systems. Moreover, we discovered a new method for producing more stable and efficient LDH-based electrodes suitable for AEMWE electrolysers (EP24382316.8 priority date: 22.03.2024).
Additionally, alternative catalysts for water oxidation, specifically Co-based and Ni-based layered hydroxides, were investigated to understand the crystallographic and geometrical influences on catalytic activity in this family of compounds (https://doi.org/10.1021/acscatal.3c01432; https://doi.org/10.1002/chem.202303146). Furthermore, we developed a new method for the on-the-fly synthesis of self-supported LDH hollow structures through controlled microfluidic reaction-diffusion conditions (https://doi.org/10.1002/smll.202307621) and explored the upscaling of different LDHs (https://doi.org/10.3762/bjnano.14.76).
In addition to these achievements, two reviews have been published exploring the influence of crystallographic phase and magnetic properties on the catalytic behavior of layered hydroxides (https://doi.org/10.1016/j.clay.2023.107073; https://doi.org/10.1002/ejic.202400754). In line with the goal of continuous improvement and remaining at the forefront of knowledge, successful research on new 2D materials has been conducted. To generate 2D-2D hybrids based on the patented NiFe-LDH, the colloidal synthesis of a hexagonal hybrid bismuthene has been reported (https://doi.org/10.1021/jacs.2c13036). Remarkably, this material exhibits in-plane metallic characteristics, signifying its suitability as a conductive additive in hydrogen production.
Overall, 2D4H2 has enabled the development and patenting of new high-performance LDH-based electrodes for AEMWE, as well as state-of-the-art single-cell analysis (up to several A/cm²), paving the way for the advancement of more efficient AEMWE cells and stacks.
Additionally, alternative catalysts for water oxidation, specifically Co-based and Ni-based layered hydroxides, were investigated to understand the crystallographic and geometrical influences on catalytic activity in this family of compounds (https://doi.org/10.1021/acscatal.3c01432; https://doi.org/10.1002/chem.202303146). Furthermore, we developed a new method for the on-the-fly synthesis of self-supported LDH hollow structures through controlled microfluidic reaction-diffusion conditions (https://doi.org/10.1002/smll.202307621) and explored the upscaling of different LDHs (https://doi.org/10.3762/bjnano.14.76).
In addition to these achievements, two reviews have been published exploring the influence of crystallographic phase and magnetic properties on the catalytic behavior of layered hydroxides (https://doi.org/10.1016/j.clay.2023.107073; https://doi.org/10.1002/ejic.202400754). In line with the goal of continuous improvement and remaining at the forefront of knowledge, successful research on new 2D materials has been conducted. To generate 2D-2D hybrids based on the patented NiFe-LDH, the colloidal synthesis of a hexagonal hybrid bismuthene has been reported (https://doi.org/10.1021/jacs.2c13036). Remarkably, this material exhibits in-plane metallic characteristics, signifying its suitability as a conductive additive in hydrogen production.
Overall, 2D4H2 has enabled the development and patenting of new high-performance LDH-based electrodes for AEMWE, as well as state-of-the-art single-cell analysis (up to several A/cm²), paving the way for the advancement of more efficient AEMWE cells and stacks.
One of the most significant outcomes of this project has been the development of an innovative process for synthesizing high-performance, stable, and binder-free electrodes suitable for operation at high current densities (tested up to 5 A/cm² in alkaline conditions). As optimizing single cells for stable long-term measurements is costly, this project has also contributed to the design of new AEMWE cells capable of testing under commercially viable alkaline conditions.
Ongoing work is being carried out in close collaboration with research institutions and private companies. Additionally, considering that the material used as an anode is a benchmark material, along with the advancements achieved in stack component design, this project has the potential to lead to the development of a more efficient and reliable AEM stacks.
Ongoing work is being carried out in close collaboration with research institutions and private companies. Additionally, considering that the material used as an anode is a benchmark material, along with the advancements achieved in stack component design, this project has the potential to lead to the development of a more efficient and reliable AEM stacks.