Ti-mesh bipolar plate design and optimization for enhanced PEM electrolyzer performance in water splitting

Proton exchange membrane (PEM) electrolyzers are promising devices for hydrogen production from water splitting, but their performance and stability are still limited by various factors. This paper studies the effects of different structures on the performance of PEM electrolyzers, focusing on the working temperature, water conductivity, and the structure of bipolar plate. The results show that higher temperature and lower water conductivity enhance the electrolyzer performance, by increasing the catalyst activity and the proton transport. Moreover, a novel structure using a platinum-coated titanium mesh-based bipolar plate is proposed and tested. This structure improves the performance of the electrolyzer, by optimizing the mass transport, pressure drop, and water management in the electrolyzer. A 23-cell electrolyzer with this structure is developed and demonstrated. The electrolyzer achieves a high performance and stability, with a cell voltage of 1.742 V, a voltage efficiency of 85.0%, and a hydrogen production rate of 1.14 Nm³/h at 0.99 A/cm². The observed cell voltage for the PEM electrolyzer is consistent with the documented range, typically spanning from 1.55 to 1.90 V at a current density of 0.99 A/cm². This suggests that our bipolar plate design simplifies PEM electrolyzer manufacture while maintaining comparable performance to existing electrolyzers.