Impact of Electrode Support Internal Geometry on Polarisation Curve Performance in Alkaline Electrolysers

This study details the design, fabrication, and experimental validation of three unique alkaline electrolysers, each featuring a modified internal electrode-support geometry. Their performance was comprehensively assessed through polarisation curve analysis in individual, partial, and global configurations. The development followed the Advanced Product Quality Planning (APQP) methodology, employing pure nickel electrodes to ensure stability. The results demonstrate that specific geometric alterations directly influence electrochemical performance and overall efficiency. By operating three electrolysers simultaneously, the system achieved an overall efficiency of 42% and a maximum oxyhydrogen production rate of 10 L·min−1, with minimal electrolyte carryover. This systematic work establishes essential design guidelines to advance the technology from Technology Readiness Level (TRL) 5 to TRL 6, facilitating the development of a reliable 5 kW hydrogen production system.