- Research Article
- 10.1149/ma2025-02422084mtgabs
Selective Gas Permeability Membranes for Advanced Alkaline Water Electrolyzers
- Nov 24, 2025
- Electrochemical Society Meeting Abstracts
- Ashraf Abdelhaleem + 8 more +8
The development of high-performance membranes for alkaline water electrolysis (AWE) is crucial for scaling up green hydrogen production. Conventional porous diaphragms used in AWE must balance ionic conductivity and gas crossover suppression, where increased porosity enhances conductivity but compromises gas separation efficiency. This study introduces an innovative membrane with selective gas permeability, enabling efficient operation under industrial conditions with enhanced durability.The proposed membrane exhibits anisotropic gas permeability, meaning it preferentially suppresses gas crossover in one direction more than the other [1]. This effect is achieved by a unique asymmetric structure, where one side of the membrane is smoother and denser, acting as an effective gas barrier, while the other side remains more porous to maintain high ionic conductivity. Notably, the membrane's ionic resistance (0.2 Ω cm²) is comparable to that of the commercial Zirfon Perl UTP500 diaphragm, while simultaneously demonstrating superior gas crossover mitigation.To assess performance, the membrane was tested in a 4-cell alkaline water electrolyzer stack under various operating conditions. Gas purity measurements confirmed that the membrane orientation significantly influences gas separation efficiency. In orientation-2 (smooth side facing the anode), H₂ permeation to the anode side was significantly reduced, as shown in Figure 1(a), while maintaining hydrogen purity above 99.6 vol% even at low current densities. Conversely, in orientation-1 (smooth side facing the cathode), H₂ purity approached nearly 100 vol% due to the substantial suppression of oxygen crossover, as illustrated in Figure 1(b). Furthermore, the flux density of permeated H₂ remained largely unaffected by current density in both orientations, as shown in Figure 1(c), indicating that hydrogen crossover was primarily governed by diffusion rather than electrochemical driving forces. In contrast, the flux density of permeated O₂ increased significantly with current density in orientation-2, as depicted in Figure 1(d), suggesting a strong correlation with electro-osmotic drag effects. These results highlight the membrane’s ability to extend the operational range of alkaline electrolyzers while reducing the risk of explosive gas mixtures.The durability of the membrane was evaluated over 900 hours of continuous operation at 1.0 A cm⁻² in 7 M KOH at 60 °C, demonstrating stable performance without significant degradation. Furthermore, pre-treatment studies revealed that soaking the membrane in pure water for one day significantly improved its ionic conductivity, making it compatible with commercial electrolyzer systems.This research demonstrates that integrating a selective gas permeability membrane into alkaline water electrolyzers can enhance efficiency, improve hydrogen purity, and extend operational flexibility, particularly under fluctuating renewable energy conditions. These findings contribute to the advancement of low-cost, durable, and scalable electrolysis technologies, supporting the widespread adoption of green hydrogen in a future hydrogen economy. Acknowledgments: This research was partially supported by JPNP 20003 project that was commissioned by the New Energy and Industrial Technology Development Organization (NEDO).
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