Corrosion-resistant NiFe anode towards kilowatt-scale alkaline seawater electrolysis

Development of large-scale alkaline seawater electrolysis requires robust and corrosion-resistant anodes. Here we propose engineering NiFe layered double hydroxide (LDH)-based anodes by incorporating a series of anions into the LDH interlayers. The most optimal NiFe LDH anode with intercalated phosphates demonstrates stable operation at a high current density of 1.0 A cm^-2 for over 1000 hours in a 2 W-scale alkaline seawater electrolyzer (ASWE). Fundamental studies indicate that the basicity, indicated by pK_a values, of the intercalated anions in NiFe LDH governs its oxygen evolution reaction activity and corrosion resistance. Highly basic anions (i.e., phosphates) securely anchor Fe sites and facilitate proton transfer to boost both durability and activity. Notably, we demonstrate the proof-of-concept for the NiFe anode in an industrial 1 kW-scale ASWE stack (1,081.2 cm² anode area in total). This unit achieves a stable operating current density of 0.5 A cm^-2 at about 2.0 V, twice that of the commercial alkaline pure water electrolyzer, contributing to an economically competitive hydrogen production cost of US$ 1.96 kg_H2^-1.