Enhancing electrolysis performance: Nanoparticles and micro-arc oxidation in green hydrogen generation

• Micro-Arc Oxidation (MAO) enhances aluminum electrodes by improving corrosion resistance and durability, with optimal hydrogen production observed at 15–30 minutes of oxidation. • Nanoparticle integration significantly boosts hydrogen production , with ZnO increasing output by 745% and CuO by 107%, while their combination yields even higher efficiency. • Optimizing potassium hydroxide (KOH) concentration at 2.5% maximizes hydrogen production, highlighting the crucial role of electrolyte composition in electrolysis efficiency. • Combining MAO-treated electrodes with nanoparticles results in superior hydrogen generation, reaching up to 15 ml/min, demonstrating the effectiveness of hybrid electrolysis systems. • This study presents a scalable and sustainable approach to green hydrogen production by integrating surface-treated aluminum electrodes with nanoparticle-enhanced electrolytes. Green hydrogen is vital for the global energy transition, offering a sustainable and emissions-free alternative to fossil fuels. This research aims to enhance the performance of alkaline electrolysis systems and reduce their cost by exploring two key strategies: improving aluminum electrodes through surface treatment and integrating nanomaterials into the process. To address material degradation and efficiency challenges, aluminum electrodes were treated using micro-arc oxidation (MAO), which created a corrosion-resistant ceramic-like surface layer. This treatment increased electrode durability and enhanced interaction with the electrolyte, significantly boosting hydrogen production. Additionally, incorporating nanomaterials such as copper oxide and zinc oxide nanoparticles optimizes electrochemical activity, reduces energy requirements, and improves system performance. Experimental results confirmed the efficiency of these enhancements. MAO-treated electrodes improved hydrogen output by up to 30% at lower potassium hydroxide (KOH) concentrations and maintained a 5% boost even at higher concentrations. Including nanoparticles provided remarkable results: copper oxide increased hydrogen production by 107%, while zinc oxide achieved an astounding 745% improvement. These findings underscore the transformative potential of these techniques in advancing clean hydrogen production technologies.