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DOE OSTI2026

Coupled Interfacial Kinetics and Transport Resistances Govern High-Current Behavior in Bipolar Membranes

Bipolar membranes (BPMs) enable electrochemical systems that operate across large pH gradients; however, high-current operation is often limited by voltage losses whose origins remain difficult to resolve in membrane−electrode assemblies. Here, we combine electrochemical impedance spectroscopy with distribution of relaxation times (EIS–DRT) analysis and operando synchrotron X-ray diffraction to examine interfacial polarization, membrane hydration, and transport in commercial and synthesized BPMs. EIS–DRT isolates the BPM-associated interfacial contribution and shows that the commercial BPM exhibits larger water-dissociation-associated overpotentials than the synthesized BPM. Operando hydration mapping shows that both membranes retain water at the bipolar junction during high-current operation, while anode-adjacent hydration gradients are more pronounced in the commercial membrane. These results indicate that high-current voltage losses are not governed by junction water starvation alone but by coupled interfacial polarization and transport resistances.

36 MATERIALS SCIENCE↗

DOE OSTI2026

How Does Water Dissociation Work in Bipolar Membranes?

Bipolar membranes (BPMs) create counteracting spatial gradients of pH and electrostatic potential in electrochemical systems, enabling applications in pH regulation, electrocatalysis, and separations. At the polarized junction of a BPM the water dissociation (WD, 2H2O ⇌ H3O+ + OH-) reaction can be driven, but it remains poorly understood. In this Perspective, we integrate molecular insights from bulk-water autoionization and the associated field effects with continuum descriptions of BPM electrostatics and experimental WD kinetic analyses to describe possible mechanisms of voltage-driven WD. Pristine BPM junctions highlight both the limits of primarily electric-field-driven WD and the practical challenges of junction stability at extreme reverse bias. Introducing heterogeneous catalyst layers, commonly metal oxides and graphene oxides, accelerates WD by orders of magnitude through hypothesized coupled effects in which surface acid-base functionality and high-density hydroxyl sites mediate proton-transfer steps, and catalyst mobile electronic/ionic charges redistribute the junction electric potential drop to shape the local electric fields and reactive microenvironments. Kinetic analyses suggest two regimes of heterogeneous WD mechanism, including field-driven ordering of interfacial water and a Second-Wien-Effect dissociation-barrier lowering. We conclude by defining the key unknown variables (local pH, electrostatic potential, catalyst charge state and relationships among mechanisms) and outlining experimental and multiscale modeling strategies needed for predictive WD catalysis and for controlling related ion-transfer reactions.

Wu, Yifan↗

DOE OSTI2024

Local ionic transport enables selective PGM-free bipolar membrane electrode assembly

Bipolar membranes in electrochemical CO 2 conversion cells enable different reaction environments in the CO 2 -reduction and O 2 -evolution compartments. Under ideal conditions, water-splitting in the bipolar membrane allows for platinum-group-metal-free anode materials and high CO 2 utilizations. In practice, however, even minor unwanted ion crossover limits stability to short time periods. Here we report the vital role of managing ionic species to improve CO 2 conversion efficiency while preventing acidification of the anodic compartment. Through transport modelling, we identify that an anion-exchange ionomer in the catalyst layer improves local bicarbonate availability and increasing the proton transference number in the bipolar membranes increases CO 2 regeneration and limits K + concentration in the cathode region. Through experiments, we show that a uniform local distribution of bicarbonate ions increases the accessibility of reverted CO 2 to the catalyst surface, improving Faradaic efficiency and limiting current densities by twofold. Using these insights, we demonstrate a fully platinum-group-metal-free bipolar membrane electrode assembly CO 2 conversion system exhibiting <1% CO 2 /cation crossover rates and 80-90% CO 2 -to-CO utilization efficiency over 150 h operation at 100 mA cm -2 without anolyte replenishment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Enabling Roll-to-Roll Manufacturing of Bipolar Membranes Using Microscopy

Bipolar membranes (BPMs) used for water treatment suffer from interface instabilities, causing premature failure and decreased performance. Recent research has highlighted the impacts of membrane morphology on mechanical behavior and performance. Improved material performance of thin film membranes requires enhanced transport properties coupled with better control of the mechanical characteristics to avoid premature failure of the film. Thus, morphology is a key parameter when developing and evaluating novel membrane materials. Microscopy offers unique advantages for nano-scale characterization of thin film membrane interfaces and morphologies. In this study, the interface junction of BPMs was evaluated using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX). BPMs were fabricated using (1) hot pressing lamination, (2) bench-scale solution casting, and (3) roll-to-roll sequential casting (R2R). Both commercial and in-house fabricated ion exchange membranes were used in the BPMs. The BPMs were comprised of a cation exchange membrane and an anion exchange membrane with a catalyst layer sandwiched in between. Cross sectional SEM and EDX images of the membrane interface junction were compared among the different fabrication techniques and materials. The bench cast catalyst layers were nonuniform compared to the R2R and hot pressed membranes, demonstrating the importance of precise catalyst application conditions. Different thicknesses of the BPMs and individual membrane layers revealed that polymer solution concentration needs to be optimized during manufacturing. This work shows that microscopy can identify key processing parameters that affect BPM interface junction quality at the microscale to enable manufacturing of high performance BPMs.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Comparing Advanced Bipolar Membranes for High-Current Electrodialysis and Membrane Electrolysis

Advanced bipolar membranes (BPMs) with low water-dissociation overpotential (ηwd) may enable new electrochemical technologies for electrolysis, fuel cells, acid–base synthesis, brine remediation, lithium-battery recycling, and cement production. However, these advanced BPMs have only been demonstrated in BPM water electrolysis (BPMWE) configurations where the BPM is under static compression by the porous-transport layers. It is important to study these BPMs in applications like electrodialysis where large degrees of static compression are not possible. We present a BPM electrodialysis (BPMED) platform to measure water-dissociation overpotential (ηwd) and compare BPMWE and BPMED systems. We show advanced BPMs with half the ηwd compared to commercial BPMs for BPMED while maintaining ∼90% current efficiency from 0.05–0.5 A cm–2. The BPMED ηwd values are, however, about 0.2 V higher at 0.5 A cm–2 than those for BPMWE. Regardless, these results show that BPMs developed and optimized in BPMWE applications are well-suited for next-generation high-current-density BPMED technologies.

Vulpin, Olivia T↗

DOE OSTI2026

Enabling Bipolar Membrane Manufacturing Using Microscopy

36 MATERIALS SCIENCE↗

DOE OSTI2024

Ion-specific phenomena limit energy recovery in forward-biased bipolar membranes

The ability for bipolar membranes (BPMs) to interconvert voltage and pH makes them attractive materials for use in energy conversion and storage. Reverse-biased BPMs, which use electrical voltage to dissociate water into acid and base, have become increasingly well studied. However, forward-biased BPMs (FB-BPMs), in which voltage is extracted from pH gradients through recombination, require further study. Here physics-based modeling elucidates how the complex coupling of transport and kinetics dictates the performance of FB-BPMs in electrochemical devices. Simulations reveal that the open-circuit potential of FB-BPMs is dictated by the balance of ion recombination and crossover, where recombination of buffering counter-ions attenuates the open-circuit potential. Counter-ion mass-transport limitations and uptake of ionic impurities limit achievable current densities by reducing the applied pH gradient or the available fixed-charge sites that mediate recombination. Further, the model highlights the importance of selective ion management in mitigating energy losses and provides insight into the rational material design of FB-BPMs for energy applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Bipolar Membranes With Controlled, Microscale 3D Junctions Enhance the Rates of Water Dissociation and Formation

A soft lithographic method is developed for making bipolar membranes (BPMs) with catalytic junctions formed from arrays of vertically oriented microscale cylinders. The membranes are cast from reusable polydimethylsiloxane (PDMS) molds made from silicon masters, which are fabricated on 2" to 4" wafer scales by nanosphere lithography. High-aspect-ratio junctions are made on a length scale similar to the thickness of optimized catalyst layers for water dissociation, creating a platform for probing the dual effects of catalysis and local electric field at the microscale BPM junction. Optimized polymer materials and nanoscale metal oxide catalysts are used in this study. 3D BPMs are tested under reverse and forward bias conditions, exhibiting superior performance relative to their 2D counterparts. Under forward bias in H 2- O 2 fuel cells, 3D BPMs achieve a current density of 1500 mA cm –2 , ≈7 times higher than 2D membranes made from the same materials.

25 ENERGY STORAGE↗

DOE OSTI2025

Optimal design of power constrained bipolar membrane electrodialysis over a wide brine range

Bipolar membrane electrodialysis enables the in-situ production of high value products (e.g., acid and base) from clean brine, which is essential for a sustainable future. A technoeconomic assessment (TEA) was conducted on extraction of value from brine using the WaterTAP framework to identify optimal cost across a wide design space. Here, in the power constrained regime, increasing supplied salt concentration does not necessarily result in reduced cost or increased NaOH concentration. A detailed analysis elucidates the critical roles of water dissociation, limiting currents, and sodium diffusion play in shaping the landscape of levelized cost. Among these, water splitting predominantly influences the TEA outcomes across most of the optimal design space. Sensitivity analysis further demonstrates that membrane properties controlling water dissociation significantly impact the unit cost. The results indicate that innovations targeting improvements in water disassociation should be prioritised to effectively reduce the levelized cost of product production.

Bipolar membrane electrodialysis↗

DOE OSTI2026

Comparison of the Effects of Bipolar Membrane Preparation Conditions on the Mechanical Durability and Electrochemical Performance for Electrodialysis Applications

Bipolar membranes (BPMs) are enabling materials for electrochemical conversion technologies such as water electrolysis, fuel cells, CO 2 electrolysis, and electrodialysis (ED) for direct air/ocean capture of CO 2 . However, current BPM durability can suffer from chemical, mechanical, and performance degradation when operated at high current density (ion flux) and physical scale. Therefore, this limits its adoption in a wider applications space. BPMs have several known degradation mechanisms, including chemical breakdown of ion-exchange polymers, loss of junction adhesion, or physical breakdown due to shearing force and pressure swings in an electrodialysis cell. To assess the electrochemical stability and mechanical durability of BPMs under operational conditions, we investigated how fabrication conditions (including preconditioning, hot-pressing temperature and pressure, and catalyst loading) impact the adhesion of custom-made BPMs. T-peel studies were performed ex situ to quantify adhesive forces of BPMs, and bipolar membrane electrodialysis (BPMED) experiments were performed to assess the electrochemical performance of the corresponding BPMs. The results of this systematic comparison indicate that hydration and heated pressing create improved adhesion during the fabrication of BPMs, and BPMED testing shows that these fabrication techniques are not detrimental to the electrochemical performance of the BPMs.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Measuring pH Changes Inside a Bipolar Membrane Junction

Here, the local pH environment within bipolar membrane (BPM) junctions is complex and not well understood, yet it is important to control for advancing the performance of BPM-based electrochemical systems. We report a voltammetric strategy using an ultrathin Ni mesh pH probe to spatially resolve pH changes in the BPM junction during model BPM electrolyzer operation. Under reverse bias, we observe depletion of OH – at the anion-exchange layer (AEL) interface, with a degree diminishing with increasing distance from the AEL. These gradients correlate with current-dependent water dissociation (WD) and are modulated by the electric field and the surface charge state of the catalyst. By correlating spatial pH profiles with the surface-charging behavior of WD catalysts, we explore a mechanism of catalyst-mediated H + and OH – transfer facilitated by hydrogen-bonding networks. These findings highlight the role of local chemistry and electrostatics in BPM performance and offer new methods to probe and engineer catalytic junctions in electrochemical energy devices.

Hou, Shujin [University of California, Berkeley, C↗

DOE OSTI2026

Nanometer Scale Imaging to Develop Quantitative Descriptors of Bipolar Membrane Junction Structure

Swings in pH can be achieved by electrically polarizing a bipolar membrane (BPM) to drive water dissociation at the BPM junction for electrochemical conversion and separation processes. BPM junction design is critical to tailor performance for specific applications; however, characterization techniques capable of resolving the nanometer scale physical structure of the junction are limited. We present sample preparation, imaging, and analysis workflows that are adaptable to a variety of BPM junction architectures. Atomic force microscopy produces BPM junction images with nanometer scale lateral resolution for samples with and without a graphene oxide water dissociation catalyst in the junction. Subsequent image segmentation and analysis quantify line edge roughness and catalyst layer thickness as descriptors of junction structure. Comparison of pre- and post-electrodialysis junctions suggests electric field-induced alignment of catalyst particles during electrodialysis. This characterization workflow can inform manufacturing protocols, computational modeling, and failure mode analysis for next-generation BPMs.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Asymmetric Bipolar Membrane for High Current Density Electrodialysis Operation with Exceptional Stability

Bipolar membranes (BPMs) enable isolated acidic/alkaline regions in electrochemical devices, facilitating optimized environments for electrochemical separations and catalysis. For economic viability, BPMs must attain stable, high current density operation with low overpotentials in a freestanding configuration. We report an asymmetric, graphene oxide (GrOx)-catalyzed BPM capable of freestanding electrodialysis operation at 1 A cm–2 with overpotentials <250 mV. Use of a thin anion-exchange layer improves water transport while maintaining near unity Faradaic efficiency for acid and base generation. Voltage stability exceeding 1100 h with an average drift of 70 μV/h at 80 mA cm–2 and 100 h with an average drift of −300 μV/h at 500 mA cm–2 and implementation in an electrodialysis stack demonstrate real-world applicability. Continuum modeling reveals that water dissociation in GrOx BPMs is both catalyzed and electric-field enhanced, where low pK a moieties on GrOx enhance local electric fields and high pK a moieties serve as active sites for surface-catalyzed water dissociation. These results establish commercially viable BPM electrodialysis and provide fundamental insight to advance design of next-generation devices.

Lucas, Éowyn↗

DOE OSTI2026

Data supporting the manuscript "Nanometer Scale Imaging to Develop Quantitative Descriptors of Bipolar Membrane Junction Structure"

This dataset contains atomic force microscopy images associated with the manuscript "Nanometer Scale Imaging to Develop Quantitative Descriptors of Bipolar Membrane Junction Structure" by Maria Kelly, Emily R. Dunn, Ellis A. Spickermann, Josephine N. Gruber, César A. Lasalde-Ramírez, P. N. Romero Zavala, Éowyn Lucas, Ankur Gupta, Harry A. Atwater, and Wilson A. Smith. The dataset contains both raw images as well as segmented images produced by the image processing workflow described in the manuscript. A readme file and meta data file are included to provide additional details regarding the sample identity, image acquisition parameters, and file naming scheme.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Bipolar Membranes Electrodialysis for Water Purification and Resource Recovery

Reverse osmosis concentrate (ROC) from inland brackish water desalination and wastewater recycling presents moderate salinity, posing significant challenges for treatment and disposal. Existing treatment technologies predominantly rely on energy-intensive thermal methods, large-area evaporation strategies, or deep-well disposal, which often result in the loss of water value. Electrified membrane brine treatment offers a promising alternative by utilizing renewable energy sources, enabling complete water recycling. This work proposes the development of next-generation bipolar membrane electrodialysis (BMED) systems capable of desalinating brine while simultaneously recovering valuable resources. However, several critical challenges remain in the areas of membrane engineering for BMED. These include: 1) decreased current efficiency during desalination due to the low conductivity of feed chambers, 2) fouling and scaling from multivalent ions and contaminants in the feed, and 3) the retention and carryover of ROC contaminants, including PFAS compounds. Our research focuses on the development of novel anion exchange membranes (AEMs) and cation exchange membranes (CEMs) based on synthesized multiblock copolymers. We investigate the effects of block length, ion exchange capacity (IEC), and polymer backbone structure on cation and anion transport (e.g., Na+, Cl-, OH-, H+) for both our synthesized membranes and commercial membranes. Fundamental properties of these membranes, such as water uptake, IEC, and ionic conductivity, are also evaluated to optimize performance for BMED applications.

08 HYDROGEN↗

DOE OSTI2025

High‐Concentration Alcohol Generation in Bipolar Membrane CO Electrolyzer

Electrochemical reduction of carbon dioxide and carbon monoxide offers an electricity‐powered route to make multicarbon liquid products. However, in conventional systems employing anion exchange membranes (AEMs), significant liquid product crossover leads to dilute product streams, increasing separation costs; and also produces unwanted anodic oxidation, further decreasing overall efficiency. Here, we report a forward‐biased bipolar membrane (FB‐BPM) system that achieves <10% liquid product crossover while sustaining a highly alkaline environment near the cathode, suppressing ethylene and hydrogen and favoring liquid products. By tuning catalyst composition to modulate the adsorption of *H and *OH, we steer selectivity toward acetate and alcohols. Using the FB‐BPM system, we achieve >25 wt% acetate on CuZn and >15 wt% alcohols on CuSn directly from the cathode outlet stream.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Bipolar Membrane Electrodialyzers as Flexible Demand Response Resources: Co-Optimization of Cost Savings and Product Formation

Bipolar membrane electro dialyzers (BPMED) are widely used for chemical production and processing, including in the emerging ocean alkalinity enhancement (OAE) industry. In this paper, we explore the potential of BPMED devices as flexible electrochemical loads within power system operations. Using a multi-objective optimization framework, we evaluate BPMED operation across 24-hour and monthly horizons to examine how dispatch strategies respond to electricity price and grid conditions. Simulation results show that altering the relative weights of the choices in the objective function strongly shape the operating patterns, with cost-focused strategies that suppress the operation during peak prices. Furthermore, we propose alternative formulations that optimize operations to achieve both cost savings and alignment with periods of lower grid-side carbon intensity (CI), as low grid-side CI is key to maximize OAE efficiency. Additionally, a detailed sensitivity analysis highlights the importance of device properties, where low area-specific resistance (ASR) of membrane and high current efficiency (CE) are observed to jointly unlock cost-effective operation. However, even modest shunt efficiency losses are observed to erode performance and decrease system value. Importantly, the analysis demonstrates that BPMED can serve as a controllable and flexible demand response resource, shifting load to support multiple grid-side objectives, including (but not limited to) renewable integration, alleviate peak demand, and provide co-benefits for system reliability. These findings underscore BPMED’s dual role as a process technology and a grid-supporting asset, pointing to promising pathways for operational optimization of multiple objectives.

Bhattacharya, Saptarshi (ORCID:0000000308902060)↗

DOE OSTI2024

Local Electric Field Effects on Water Dissociation in Bipolar Membranes Studied Using Core–Shell Catalysts

The local electric field strength is thought to affect the rate of water dissociation (WD) in bipolar membranes (BPMs) at the catalyst–nanoparticle surfaces. Here, we study core–shell nanoparticles, where the core is metallic, semiconducting, or insulating, to understand this effect. The nanoparticle cores were coated with a WD catalyst layer (TiO2 or HfO2) via atomic layer deposition (ALD), and the morphology was imaged with transmission electron microscopy. Irrespective of the core material, these core–shell catalysts displayed comparable WD overpotentials at optimal mass loading, despite the hypothesized differences in the electric field strength across the catalyst particle suggested by continuum electrostatic simulations. Substantial atomic interdiffusion between the core and shell was ruled out by X-ray absorption spectroscopy, X-ray photoelectron spectroscopy, and diffuse reflectance optical measurements. However, the optimal mass loading of catalyst was roughly 1 order of magnitude higher for the conductive and high dielectric core materials than for the low dielectric insulating cores. These findings are consistent with the hypothesis that electric field screening within the core material focuses the electric field drop between particles such that larger film thicknesses can be tolerated. Collectively, these data support the idea that it is the local electric field at the molecular level that controls proton-transfer rates and that the metal core/dielectric-shell constructs introduced here modulate that field. Further materials and synthetic design may enable optimization of the electric field strength across the proton-transfer trajectory at the material surface.

Sarma, Prasad V↗