An experimental performance evaluation of newly designed flow-through electrodes for hydrogen production

This study reports a unique flow-through electrode design for hydrogen production in alkaline water electrolysis. This paper investigates a variety of electrodeposition coatings on the 3D-printed electrodes, including nickel, nickel-copper, and nickel-iron. The catalytic activity and properties of the electrodes are examined through electrochemical measurements involving linear sweep voltammetry, cyclic voltammetry, electrochemical impedance spectroscopy, and surface morphology analysis. An experimental setup is also developed to measure hydrogen production and evaluate the efficiency of the designed electrodes. The study finds the flow-through electrodes coated with nickel-copper and nickel-iron achieve the current densities of 54 mA/cm 2 and 45 mA/cm 2 , respectively. The activation overpotentials for the nickel-copper coated electrode are reported as 539 mV, and 408 mV for the nickel-iron coated electrode, both at a current density of 10 mA/cm 2 . The highest production rate is obtained within the first 15 minutes, 0.273 μg/s for the Ni-Cu flow-through electrode and 0.255 μg/s for the Ni-Fe flow-through electrode. The study further shows that flow-through electrodes produce hydrogen with an efficiency approximately 74% higher than traditional electrodes, suggesting a potentially better design for better hydrogen production in industrial applications. • This study reports a new flow-through electrode design for hydrogen production. • The electrodes are fabricated using 3D-printing and coated using electrodeposition. • The performance is evaluated using electrochemical and hydrogen measurements. • The study finds that flow-through electrodes perform better than traditional. • The flow-through electrodes consume less energy with the same or higher production.