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<p>Bubbles accumulation in the electrode limits anion exchange membrane water electrolyzer performance at industrial current densities (&gt;1.0 A cm<sup>-2</sup>). Currently, conventional electrode designs prioritize the optimization of the electrochemically active surface area. However, this study reveals that bubble dynamics matters high-rate water electrolysis efficiency in anode-feeding mode in three ways:1) cover active sites at the anode; 2) hinder water diffusion through the membrane; 3) cause water shortage at the cathode. Based on this mechanism, we propose an easy-to-prepare gradient stainless steel square hole mesh electrode. It not only offers a low cost ($8-150/m<sup>2</sup>), but also improves bubble dynamics. As a result, it reduces the cell voltage by 0.14 V at a current density of 5.0 A cm<sup>-2</sup>, even with a lower electrochemically active surface area compared to the stainless steel felt electrode. And it maintains a stable operation over 400 hours. This work redefines electrode engineering paradigms, shifting focus from electrochemically active surface area-centric approaches to two-phase flow management in water electrolyzers for industrial current densities-scale hydrogen production.</p>

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Bubble dynamics matters at high-rate water electrolysis

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年2月3日

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  • Lizhen Wu,
  • Qing Wang,
  • Shu Yuan,
  • Wenzhi Li,
  • Xiaohong Zou,
  • Mingcong Tang,
  • Kouer Zhang,
  • Xiaohui Yan,
  • Liang An

摘要

Bubbles accumulation in the electrode limits anion exchange membrane water electrolyzer performance at industrial current densities (>1.0 A cm-2). Currently, conventional electrode designs prioritize the optimization of the electrochemically active surface area. However, this study reveals that bubble dynamics matters high-rate water electrolysis efficiency in anode-feeding mode in three ways:1) cover active sites at the anode; 2) hinder water diffusion through the membrane; 3) cause water shortage at the cathode. Based on this mechanism, we propose an easy-to-prepare gradient stainless steel square hole mesh electrode. It not only offers a low cost ($8-150/m2), but also improves bubble dynamics. As a result, it reduces the cell voltage by 0.14 V at a current density of 5.0 A cm-2, even with a lower electrochemically active surface area compared to the stainless steel felt electrode. And it maintains a stable operation over 400 hours. This work redefines electrode engineering paradigms, shifting focus from electrochemically active surface area-centric approaches to two-phase flow management in water electrolyzers for industrial current densities-scale hydrogen production.