Zero Emission Fuels B.V. (ZEF) is developing an integrated micro-plant to produce methanol from captured CO2 and green Hydrogen produced via alkaline water electrolysis. The electrolysis unit represents one of the largest financial and energetic costs in the system and is required to operate at 166 mA/cm2 under 2 V. In order to decrease the costs, ZEF is looking to synthesize highly efficient nickel-based electrodes to avoid using expensive noble-metal ones.
The objective of this work was the synthesis of efficient and stable nickel-based electrodes. Two electrodes were synthesized through electrodeposition (Raney nickel and NiFe) and one was synthesized through hydrothermal treatment (NiFe-LDH) and were compared to a RuO2-containing (Permascand) electrode and to a smooth nickel electrode. On/off cycles for 2.5 hours were carried out to measure the stability of the electrodes. Additionally, performance tests in a pressure range of 1-5 bar were carried out to measure the effect of increasing pressure. The experiments were carried out in an in-house designed and built zero-gap alkaline electrolysis cell.
Raney nickel, with a measured roughness factor of 150 was the best performing of the synthesized electrodes. After the stability tests, it was able to produce 166 mA/cm2 at 1.9 V (1.73 and 2.12 V for Permascand and smooth nickel, respectively). Raney nickel as anode material presented significant degradation. Raney nickel is the most promising material for HER, none of the synthesized materials presented significant stability for OER.
From the nickel-iron electrodes, NiFe with a roughness factor of 19.5 presented the best performance of the synthesized materials with 2.04 V for the mentioned current density. NiFe presented significant degradation, especially as anode material. NiFe presented a relative high performance considering its low electrochemical active surface area attributed to the presence of highly efficient active sites. NiFe-LDH was quickly degraded during the tests as cathode and anode material.
The pressure tests showed an inverse relationship between voltage and pressure. This hints that a decrease in bubble size with pressure is the cause behind the decrease in voltage. A simple model, based on experimental data and thermodynamic considerations, estimated that operating the cell at 50 bar reduces the voltage by 0.25 V compared to operation at 1 bar. The estimated reduction in voltage at a pressure of 50 bar would allow to operate the electrolysis cell under 2 V even with smooth nickel mesh as electrode.