Simulation-Based Performance and Cost Optimization of Alkaline Electrolyzers

The acceleration of the green energy transition has reinforced the importance of reliable, cost-effective hydrogen production technologies. Alkaline water electrolyzers (AWEs) have become a critical option due to their lack of requirement of platinum group metals, as well as their scalability; however, the materials, geometry, and operating conditions used must be comprehensively evaluated alongside electricity costs. This study presents an approach that directly integrates a COMSOL-based electrochemical polarization model with a techno-economic module and validates the results against published U–J curves and 2024 public LCOH ranges. The scans across the 25 kW–10 MW range show that temperature and separator porosity are the most powerful factors affecting performance; narrow cell gaps significantly reduce ohmic losses, and the electrolyte concentration provides limited additional benefit beyond a certain threshold. KOH outperforms NaOH under most conditions, but the difference between the two electrolytes narrows as temperature increases. Economic analyses confirm that electricity price is the dominant determinant of LCOH; levels of 4–5 $·kg−1 are achievable at the MW scale, while high-cost scenarios reach 7–10 $·kg−1. In conclusion, the study provides a validated and scalable framework for the joint optimization of AWE design and operation.