Search Results (11)

Advanced alkaline water electrolysis (AWE) in “zero-gap” configuration is a promising approach for low-temperature hydrogen production, but its efficiency strongly depends on the design and surface chemistry of nickel-based electrodes. Here, we present a simple dip-and-drying method (DDM) to modify commercial nickel foam with a Ni–FeOOH/PTFE microporous catalytic layer and evaluate its electrochemical performance in 1 M KOH and in a laboratory zero-gap cell with a Zirfon^® Perl 500 UTP diaphragm, through circulating 25 wt.% KOH. The FeSO₄-assisted DDM treatment generates mixed Ni–Fe oxyhydroxide surface species, while PTFE imparts control hydrophobicity, enhancing both catalytic activity and gas-release behavior. Annealing the electrode (DDM-NF-CAT-A) results in a cell voltage of 2.45 V at 1 A·cm⁻² and 80 °C, demonstrating moderate performance comparable to other Ni-based electrodes prepared via low-complexity methods, though below that of optimized state-of-the-art zero-gap systems. Short-term durability tests (80 h at 0.5 A·cm⁻²) indicate stable operation, but long-term industrial performance was not assessed. These findings illustrate the potential of the DDM approach as a simple, low-cost route to structured nickel foam electrodes and provide a foundation for further optimization of catalyst loading, microstructure, and long-term stability for practical AWE applications. Full article

This work demonstrates for the first time a cost-effective modification of stainless-steel electrodes with an Fe³⁺ precursor via the deep-and-dry method (DDM) at processing temperatures between 20 °C and 80 °C, enabling their simultaneous applicability for both OER and HER in zero-gap electrolyzers. The approach offers a durable and economical alternative to conventional nickel-based electrodes. Morphological and compositional analyses by scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) demonstrated a pronounced temperature-dependent evolution of surface features. At 20 °C, the coatings exhibited high porosity and incomplete coverage, whereas treatment at 60 °C yielded a compact, uniform, and continuous layer with suppressed Fe/Ni exposure and enhanced oxygen incorporation. Electrochemical characterization in 25% KOH by cyclic voltammetry and polarization measurements confirmed reversible redox behavior and comparable electrochemically active surface areas across all samples, with the 60 °C electrodes achieving the highest catalytic activity. In electrolysis cell tests (zero gap), the optimized electrodes delivered low cell voltages, current densities up to 1.35 A cm⁻², and power outputs approaching 3.5 W cm⁻². These results establish processing temperature as a decisive factor for tailoring the morphology, composition, and performance of DDM-fabricated electrodes, underscoring the promise of 60 °C-treated electrodes for efficient hydrogen production. Full article

The electrochemical reduction in CO₂ (CO2RR) to syngas and value-added hydrocarbons offers a promising route for sustainable CO₂ utilization. This work develops tuneable Cu-Sn bimetallic catalysts via electrodeposition, optimized for CO2RR in a zero-gap flow cell fed with CO₂-saturated KHCO₃ solution, a configuration closer to industrial scalability than conventional H-cells. By varying electrodeposition parameters (pH, surfactant DTAB, and metal precursors), we engineered catalysts with distinct selectivity profiles: Cu-Sn(B), modified with DTAB, achieved 50% Faradaic efficiency (FE) to CO at −2.2 V and −50 mA·cm⁻², outperforming Ag-based systems that require higher overpotentials. Meanwhile, Cu-Sn(A) favoured C₂H₄ (35% FE at −100 mA·cm⁻²), and Cu-Sn(C) shifted selectivity to CH₄ (26% FE), demonstrating product tunability. The catalysts’ performance stems from synergistic Cu-Sn interactions and DTAB-induced morphological control, as revealed by SEM/EDX and electrochemical analysis. Notably, all systems operated at lower voltages than literature benchmarks while maintaining moderate CO₂ utilization (32–49% outlet). This study highlights the potential of electrodeposited Cu-Sn catalysts for energy-efficient CO2RR, bridging the gap between fundamental research and industrial application in syngas and hydrocarbon production. Full article

Green hydrogen production from water electrolysis (WE) is one of the most promising technologies to realize a decarbonized future and efficiently utilize intermittent renewable energy. Among the various WE technologies, the emerging anion exchange membrane (AEMWE) technology shows the greatest potential for producing green hydrogen at a competitive price. To achieve this goal, simple methods for the large-scale synthesis of efficient and low-cost electrocatalysts are needed. This paper proposes a very simple and scalable process for the synthesis of nanostructured NiCo- and NiFe-based electrode materials for a zero-gap AEMWE full cell. For the preparation of the cell anode, oxides with different Ni molar fractions (0.50 or 0.85) are synthesized by the sol–gel method, followed by calcination in air at different temperatures (400 or 800 °C). To fabricate the cell cathode, the oxides are reduced in a H₂/Ar atmosphere. Electrochemical testing reveals that phase purity and average crystal size significantly influence cell performance. Highly pure and finely grained electrocatalysts yield higher current densities at lower overpotentials. The best performing membrane electrode assembly exhibits a current density of 1 A cm⁻² at 2.15 V during a steady-state 150 h long stability test with 1 M KOH recirculating through the cell, the lowest series resistance at any cell potential (1.8 or 2.0 V), and the highest current density at the cut-off voltage (2.2 V) both at the beginning (1 A cm⁻²) and end of tests (1.78 A cm⁻²). The presented results pave the way to obtain, via simple and scalable techniques, cost-effective catalysts for the production of green hydrogen aimed at a wider market penetration by AEMWE. Full article

Electrochemical separations use an ionic current to drive the flow of ions across an ion exchange membrane to produce dilute and concentrated streams. The economics of these systems is challenging because passing an ionic current through a dilute solution often requires a small cell gap to lower the ionic resistance and the use of a low current density to minimize the voltage drop across the dilute product stream. Lower salt concentration in the product stream improves the fraction of the salt recovered but increases the electricity cost due to high ohmic losses. The electricity cost is managed by lowering the current density which greatly increases the balance of the plant. The cell configuration demonstrated in this study eliminates the need to pass an ionic current through the diluted product stream. Ionic current passes only through the concentrated product stream, which allows use of high current density and smaller balance of the plant. The cell has three chambers with an anion and cation membrane separating the cathode and anode, respectively, from the concentrated product solution. The device uses zero-gap membrane electrode assemblies to improve the cell voltage and system performance. As ions concentrate in the center compartment, the solution resistance decreases, and the product is recovered with a lower voltage penalty compared to traditional electrodialysis. This lower voltage drop allows for faster feed flow rates and higher current density. Additionally, the larger cell gap for the product provides opportunities for systems with solids suspended in solution. It was found that the ion collection efficiency increased with current due to enhanced convective mass transfer in the feed streams. Full article

In this research, a thin layer of multi-metallic non-precious catalyst is prepared by electroplating from an electrolyte bath containing Ni, Co, and Fe sulfates over pressed commercial nickel foam electrode. The composition of the deposited catalytic film and its morphology are characterized by scanning electron microscopy (SEM) with energy dispersion X-ray (EDX) techniques. The efficiency of the prepared binder-free electrodes for electrochemical water splitting is investigated in a self-designed short water electrolysis stack with zero-gap configuration of the integrated single cells and hybrid electrical connections. The separator used is a commercial Zirfon Perl 500 membrane, doped with 25% KOH. The performance of the catalyst, the single cells, and the developed electrolyzer stack are examined by steady state polarization curves and stationery galvanostatic stability tests in the temperature range 20 °C to 80 °C. The NiFeCoP multi-metallic alloy demonstrates superior catalytic efficiency compared to the pure nickel foam electrodes and reliable stability with time. The single cells in the stack show identical performance and the cumulative stack parameters strictly follow the theoretical considerations. The applied hybrid electrical connections enable scaling of both the stack voltage and the passing current, which in turn ensures flexibility with regard to the input power and the hydrogen production capacity. Full article

Gas-fed reactors for CO₂ reduction processes are a solid technology to mitigate CO₂ accumulation in the atmosphere. However, since it is necessary to feed them with a pure CO₂ stream, a highly energy-demanding process is required to separate CO₂ from the flue gasses. Recently introduced bicarbonate zero-gap flow reactors are a valid solution to integrate carbon capture and valorization, with them being able to convert the CO₂ capture medium (i.e., the bicarbonate solution) into added-value chemicals, such as CO, thus avoiding this expensive separation process. We report here a study on the influence of the electrode structure on the performance of a bicarbonate reactor in terms of Faradaic efficiency, activity, and CO₂ utilization. In particular, the effect of catalyst mass loading and electrode permeability on bicarbonate electrolysis was investigated by exploiting three commercial carbon supports, and the results obtained were deepened via electrochemical impedance spectroscopy, which is introduced for the first time in the field of bicarbonate electrolyzers. As an outcome of the study, a novel low-loaded silver-based electrode fabricated via the sputtering deposition technique is proposed. The silver mass loading was optimized by increasing it from 116 μg/cm² to 565 μg/cm², thereby obtaining an important enhancement in selectivity (from 55% to 77%) and activity, while a further rise to 1.13 mg/cm² did not provide significant improvements. The tremendous effect of the electrode permeability on activity and proficiency in releasing CO₂ from the bicarbonate solution was shown. Hence, an increase in electrode permeability doubled the activity and boosted the production of in situ CO₂ by 40%. The optimized Ag-electrode provided Faradaic efficiencies for CO close to 80% at a cell voltage of 3 V and under ambient conditions, with silver loading of 565 μg/cm², the lowest value ever reported in the literature so far. Full article

Commercial bleach (3.6 wt% active chlorine) is prepared by diluting highly concentrated industrial solutions of sodium hypochlorite (about 13 wt% active chlorine) obtained mainly by bubbling chlorine gas into dilute caustic soda. The chlorine and soda used are often obtained by electrolyzing a sodium chloride solution in two-compartment cells (chlorine-soda processes). On a smaller scale, small units used for swimming pool water treatment, for example, allow the production of low-concentration bleach (0.3 to 1 wt% active chlorine) by use of a direct electrolysis of sodium chloride brine. The oxidation and degradation reaction of hypochlorite ion (ClO⁻) at the anode is the major limiting element of this two-compartment process. In this study, we have developed a new process to obtain higher levels of active chlorine up to 3.6%, or 12° chlorometric degree. For this purpose, we tested a device consisting of a zero-gap electrolysis cell, with three compartments separated by a pair of membranes that can be porous or ion-exchange. The idea is to generate in the anode compartment hypochlorous acid (HClO) at high levels by continuously adjusting its pH to a value between 4.5 and 5.5. In the cathodic compartment, caustic soda is obtained, while the central compartment is supplied with brine. The hypochlorous acid solution is then neutralized with a concentrated solution of NaOH to obtain bleach. In this work, we studied several membrane couples that allowed us to optimize the operating conditions and to obtain bleach with contents close to 1.8 wt% of active chlorine. The results obtained according to the properties of the membranes, their durability, and the imposed electrochemical conditions were discussed. Full article

The conversion of carbon dioxide into value-added products is progressively gaining momentum. Several strategies have been used to develop technologies that reduce the net emissions of CO₂. The utilisation of CO₂ could either contribute to carbon recycling. In this paper, the transformation of CO₂ was investigated in a coelectrolysis cell constituted of a solid polymer electrolyte, a carbon-supported CuO-Ag composite cathode and NiFeOx anode. Noncritical raw materials were synthesised according to the oxalate method and investigated in an alkaline environment. Low-carbon alcohols were obtained with a specific selectivity for ethanol and methanol over the CuO-Ag/KB cathode. The reaction rates at 1.6 V and 1.8 V cell voltages have been determined in steady-state experiments using NaHCO₃ supporting electrolyte recirculated at the anode. Full article

This paper communicates on an innovative, laboratory size alkaline water electrolyser (AWE) system, capable of efficiently producing ultra-pure hydrogen and oxygen gases. The system is composed of a zero-gap, bipolar-electrode stack, equipped with a polymer-based membrane, along with two drying columns for effective purification of H₂ and O₂ gaseous products. An optimal electrochemical efficiency of the electrolyser stack is provided through the employment of catalytically activated, extended surface-area nickel foam electrodes. Laboratory electrochemical examinations of the electrolyser included a series of galvanostatic AWE and alternating current (a.c.) impedance (single cell) experiments. Complementary examinations covered catalyst’s surface topography analysis by combined SEM (Scanning Electron Microscopy) and EDX (Energy Dispersive X-ray Spectroscopy) techniques along with chromatographic evaluation of the purity of hydrogen and oxygen products. Full article

A simple and low-cost alternating current (AC)-based method, without electrolyte correction, is proposed (Electrochemical Impedance Spectroscopy (EIS)-Zero Gap Cell) for the determination of ohmic contribution of diaphragms. The effectiveness of the proposed methodology was evaluated by using a commercial Alkaline Water Electrolysis (AWE) diaphragm (Zirfon^®). Furthermore, the results were compared with two conventional electrochemical methodologies for calculating the separator resistance, based on direct current (DC), and AC measurements, respectively. Compared with the previous techniques, the proposed approach reported more accurate and precise values of resistance for new and aged samples. Compared with the manufacturer reference, the obtained error values for new samples were 0.33%, 5.64%, and 41.7%, respectively for EIS-Zero gap cell, AC and DC methods, confirming the validity and convenience of the proposed technique. Full article