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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Cost estimation of balance of plant equipment scale up for proton exchange membrane water electrolyzer systems

Water electrolyzers that use electricity to split water into hydrogen and oxygen could be a key technology for increasing hydrogen supply to meet expanded and emerging market applications, although currently the capital costs of these electrolyzers are high. Here we examine cost reductions that might be achieved by scaling up proton exchange membrane (PEM) electrolyzer systems and leveraging economies of scale through balance of plant (BOP) components for system sizes between 1 MW and 1 GW. We estimate BOP equipment capital costs of about $\$$848/kW at 1 MW, potentially decreasing to $\$$87/kW at 1 GW (2022-dollar year basis) with most of the cost reduction happening as systems scale from 1 MW to 100 MW. We find that BOP subsystems hydrogen drying and water knockout benefited the most from economies-of-scale cost reductions, and piping, instrumentation, and housing and power electronics were less impacted. These cost reductions from economies of scale could be more significant than estimated cost reductions from manufacturing scale-up reported in literature. These results add to the knowledge base that could guide optimal system designs that balance process scale-up with plant modularization and numbering-up. We also estimate that scaling up BOP could potentially lower the levelized cost of hydrogen (LCOH) by $\$$1.7-$\$$4.6/kg, depending on the scale-up magnitude and the plant capacity factor.

08 HYDROGEN↗
DOE OSTI2023

Increasing the Electrolyte Salinity to Improve the Performance of Anion Exchange Membrane Water Electrolyzers

Direct operation of anion exchange membrane water electrolyzers (AEMWEs) with near-neutral pH feeds avoids the use of highly alkaline and corrosive solutions. However, using neutral pH solutions currently faces fundamental operational challenges that diminish performance and reduce long-term stability due to poor solution conductivity and low hydroxide ion concentration. Here, we showed that amending near-neutral pH solutions with low concentrations of alkali metal salts in a dry-cathode configuration substantially improved performance and stability. Adding NaClO 4 (10 mM) to the anolyte reduced the operating voltage by 0.19 to 2.58 V at 500 mA/cm 2 compared to non-saline solutions (2.77 V). However, further increases in the feed salt concentration (100 mM NaClO 4 ) reduced performance (2.64 V) due to a greater co-ion diffusion through the anion exchange membrane. Electrolyzer performance was further improved by utilizing salts with high conductivity such as KNO 3 . Using a saline anolyte reduced ohmic resistance, resulting in smaller applied voltage and energy consumption for hydrogen generation, while the combined effect of the membrane charge and the electric field direction in the dry-cathode feed configuration minimized ion crossover. Thus, increasing the salinity of near-neutral pH solutions represents a cost-effective strategy to improve the performance of AEMWE compared to ultrapure electrolytes, minimizing risks and costs associated with recirculating highly alkaline solutions.

anion exchange membrane water electrolyzer↗
NASA NTRS1992

SPE water electrolyzers in support of the lunar outpost

During the 1970s, the SPE water electrolyzer, which uses ion exchange membranes as its sole electrolyte, was developed for nuclear submarine metabolic oxygen production. These developments included SPE water electrolyzer operation at up to 3,000 psia and at current densities in excess of 1,000 amps per square foot. The SPE water electrolyzer system is now fully qualified for both the U.S. and U.K. Navies with tens of thousands of system hours accumulated at sea. During the 1980s, the basic SPE water electrolyzer cell structure developed for the Navies was incorporated into several demonstrations for NASA's Space Station Program. Among these were: the SPE regenerative fuel cell for electrical energy storage; the SPE water electrolyzer for metabolic oxygen production; and the high pressure SPE water electrolyzer for reboost propulsion reactant production. In the 1990s, one emphasis will be the development of SPE water electrolyzers for the Lunar Outposts Currently defined potential Lunar Outpost applications for the SPE water electrolyzer include: SPE water electrolyzers for metabolic oxygen and potable water production from reclaimed water; and SPE water electrolyzers operating at high pressure as part of stationary and mobile surface energy storage systems.

Mcelroy, J. F.↗
NASA NTRS1991

SPE (tm) water electrolyzers in support of mission from planet Earth

During the 1970's, the Solid Polymer Electrolyte (SPE) water electrolyzer, which uses ion exchange membranes as its sole electrolyte, was developed for nuclear submarine metabolic oxygen production. SPE water electrolyzer developments included operation at up to 3,000 psia and at current densities in excess of 1,000 amps per square foot. The SPE water electrolyzer system has accumulated tens of thousands of system hours with the Navies of both the United States and the United Kingdom. During the 1980's, the basic SPE water electrolyzer cell structure developed for the Navies was incorporated into several demonstrators for NASA's Space Station Program. Among these were: (1) the SPE regenerative fuel cell for electrical energy storage; (2) the SPE water electrolyzer for metabolic oxygen production; and (3) the high pressure SPE water electrolyzer for reboost propellant production. In the 1990's, emphasis will be the development of SPE water electrolyzers for Mission from Planet Earth. Currently defined potential applications for the SPE water electrolyzer include: (1) SPE water electrolyzers operating at high pressure as part of a regenerative fuel cell extraterrestrial surface energy storage system; (2) SPE water electrolyzers for propellant production from extraterrestrial indigenous materials; and (3) SPE water electrolyzers for metabolic oxygen and potable water production from reclaimed water.

J F McElroy↗
DOE OSTI2025

Materials Engineering for High Performance and Durability Proton Exchange Membrane Water Electrolyzers

Proton exchange membrane water electrolyzers (PEMWEs) are expected to play a crucial role in the global green energy transition during the 21st century. They provide a versatile and sustainable solution for generating hydrogen with very high purity in combination with renewable energies, such as solar and wind. Despite their promise, PEMWEs face several critical problems, including high costs, performance limitations, and durability challenges, particularly at low iridium (Ir) loading on the anode. Advancing next-generation PEMWEs requires extensive work on materials engineering of all cell components, including the catalyst layer (CL), membrane, porous transport layer (PTL), bipolar plate (BPP), and gasket. This task must be performed with the complementary contribution of different modeling and characterization techniques. This review presents a critical perspective from academia, research centers, and industry, mapping main developments, remaining gaps, and strategic pathways to advance PEMWE technology. A focus is devoted to key aspects, such as operation at low Ir loading, membrane durability, multiscale transport layers, porous and non-porous flow fields, multiphysics modeling, and multipurpose characterization techniques, which are thoroughly discussed. By unifying these topics, this review provides readers with the essential knowledge to grasp current developments and tackle tomorrow's challenges in PEMWE engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Structure of iridium oxide catalysts dictates performance differences for proton exchange membrane water electrolyzers

Proton exchange membrane water electrolyzers (PEMWEs) are promising zero-emission technologies. However, their high cost remains a barrier to widespread adoption. Iridium oxide is commonly used as an oxygen evolution reaction (OER) catalyst, and its cost and scarcity make it essential to reduce its loading while increasing its activity. Evaluation of iridium oxide activity should be carried out in the membrane electrode assembly (MEA) configuration to replicate realistic operating conditions. Herein, we present a comprehensive benchmarking framework to accurately evaluate the amorphous and crystalline iridium oxides at the MEA level. By systematically varying the catalyst loading, this study confirmed that each MEA was utilized uniformly, presenting intrinsic electrochemical properties independent of the loading. Through intrinsic charge density determined by voltammetry, we established two electrochemical descriptors to evaluate catalyst redox reactions. The mass activity was evaluated by correlating current vs. loading, and the slope provides loading-independent mass activity. The effect of the porous transport layer on OER activity was discussed, identifying a ‘background’ current at zero-loading. In conclusion, this study highlights potential pitfalls in MEA-level catalyst screening and underscores the importance of the loading study for reliable results.

Kwon, Obeen [University of California, Irvine, CA ↗
DOE OSTI2025

Enhancing water and oxygen transport through electrode engineering for AEM water electrolyzers

Anion-exchange membrane water electrolyzers (AEMWEs) can accelerate the deployment of more efficient and affordable hydrogen production solutions. Here, electrode structure is shown to affect water back-diffusion and oxygen transport, which, in return, governs overpotential behaviors in AEMWEs. Measurements indicate that electrode with copious catalytic sites produces water close to the AEM, creating a higher water gradient and driving water back-diffusion, which improves membrane hydration and mass transport. In situ measurement reveals a high pH gradient near the anode surface, which affects anode kinetics. Operando measurement shows reduced oxygen accumulation when decoupling oxygen production and transport on anode. Catalyst ink rheology and stability are tuned with additives to realize scalable fabrication of electrodes with enhanced transport features, allowing AEMWE to operate at 2 A cm−2 for over 1,000+ h at a 2.3 μV h−1 degradation rate. Analysis during and post-durability provides insights into degradation mechanisms. This work demonstrates an electrode design strategy for efficient and durable AEMWEs.

AEM↗
DOE OSTI2026

NiFeCo-based catalysts in high current zero-gap anion exchange membrane water electrolyzers

Understanding degradation mechanisms in pure water anion exchange membrane water electrolyzers is essential for developing durable and precious metal-free hydrogen production systems, yet electronic, chemical, and transport-driven pathways often occur simultaneously at the anode. To separate these effects, we establish a morphology invariant Ni/Fe/Co thin film model catalyst platform using physical vapor deposition and systematically compare composition-dependent behavior under both pure water and 0.1 M KOH feeds. Devices were operated under industrially relevant current density conditions, galvanostatically at 1 A cm −2 for 24 hours; metal dissolution, ionomer oxidation, and resistance growth were quantified using inductively coupled plasma mass spectrometry, X-ray photoelectron spectroscopy (XPS), and electrochemical impedance spectroscopy. Under pure-water operation, Ni-rich films showed voltage increases that correlated with rising total cell resistance (ΔV ≈ 243 mV, ΔR ≈ 0.17 Ω cm 2 ). Co-rich films maintained near constant voltages with minimal resistance change (ΔV < 10 mV, ΔR ≈ 0.03 Ω cm 2 ) but induced pronounced ionomer oxidation observed by XPS. In 0.1 M KOH, ionomer oxidation is suppressed, and impedance growth is minimized (<0.08 Ω cm 2 ) across all compositions, consistent with reduced transport limitations and improved ionic conduction relative to pure-water feeds. These results demonstrate how a controlled thin film model platform can isolate composition electrolyte relationships and provide mechanistic design principles for stable pure water anion exchange membrane electrolyzers.

Milenia Rojas Mendoza, B. [Stanford Univ., CA (Uni↗
DOE OSTI2025

Innovative Method for Reliable Measurement of PEM Water Electrolyzer Component Resistances

Understanding the sheet resistance of porous electrodes is essential for improving the performance of polymer electrolyte membrane (PEM) water electrolyzers and related technologies. Despite its importance, existing methods often fail to provide reliable and comprehensive data, especially for porous materials with complex morphologies and non‐uniform thicknesses. This study introduces a robust and straightforward method for determining the sheet resistance of porous electrodes using a novel probe concept based on industrial printed circuit board (PCB) technology. This probe measures resistance across ten distances, ranging from 250 µm to 2500 µm, enabling local mapping of resistance. The study focuses on the sheet resistance of key components in PEM water electrolyzers, including the gas diffusion layer (GDL), porous transport layer (PTL), and catalyst layers deposited on a membrane. Additionally, an image‐processing‐based method is presented to obtain the thickness distribution of the studied catalyst layers, facilitating a detailed analysis of the electrical in‐plane resistivity with thickness variations. Overall, this methodology has the potential to expedite material integration and bridge the gap between electrode engineering and single‐cell testing, thereby advancing the development of PEM water electrolyzers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Innovative duo-recombination layer design for effective hydrogen crossover mitigation in advanced MEAs for PEM water electrolyzers

Hydrogen crossover in proton exchange membrane water electrolyzers (PEMWEs) poses a safety hazard, reduces the overall efficiency, and limits the operational differential pressure range. Here, in this study, a membrane electrode assembly (MEA) with innovative Pt duo-recombination layer (DRL) design is developed by the unique reactive spray deposition technology (RSDT). The novel design comprises two thin RLs integrated within the volume of the membrane and has a total Pt loading of only 0.04 mg Pt cm −2 . Long-term durability test for over 3000 h is performed with as-fabricated MEA at steady-state conditions typical for an industrial hydrogen production system. The results from the durability test show that the newly developed DRL design effectively suppresses the H2 crossover to below 0.5 vol%. Furthermore, comprehensive post-test characterization of the MEA is performed and potential failure mechanisms in the Pt RLs observed during the durability test are identified and discussed in detail for the first time.

08 HYDROGEN↗
DOE OSTI2025

Importance of hydrogen oxidation reaction current in quantifying hydrogen crossover in PEM water electrolyzers at high differential pressure

Understanding hydrogen permeation in proton exchange membrane water electrolyzers (PEMWEs) operating at high differential pressures (>25 bar) is critical towards developing effective gas recombination strategies that enable safe operation and high efficiency. Developing this understanding relies on accurate quantification of hydrogen crossover rates in water electrolyzers operating under such conditions. In this work, we show that PEMWEs operating at high differential pressures exhibit noticeable hydrogen oxidation reaction (HOR) currents. As the HOR consumes part of the permeated hydrogen at the anode, neglecting HOR currents leads to severe underestimation of the hydrogen crossover rate. We implemented a new method combining hydrogen oxidation current with online gas chromatography measurements to accurately quantify hydrogen crossover rates as a function of operating current density in PEMWEs operating at high differential pressures (10–30 bar g ).

25 ENERGY STORAGE↗
DOE OSTI2023

Protocol for assembling and operating bipolar membrane water electrolyzers

Renewable energy-driven bipolar membrane water electrolyzers (BPMWEs) are a promising technology for sustainable production of hydrogen from seawater and other impure water sources. Here, we present a protocol for assembling BPMWEs and operating them in a range of water feedstocks, including ultra-pure deionized water and seawater. We describe steps for membrane electrode assembly preparation, electrolyzer assembly, and electrochemical evaluation. For complete details on the use and execution of this protocol, please refer to Marin et al. (2023).

Rios Amador, Isabela↗
DOE OSTI2024

Life-cycle analysis of hydrogen production from water electrolyzers

The United States' focus on decarbonization has spawned interest among policymakers in deploying water electrolysis technology for clean hydrogen production. However, water electrolyzers also raise concerns regarding their substantial use of carbon-intensive materials. Here, we conduct a comprehensive life-cycle analysis (LCA) of three prominent water electrolyzer technologies to investigate the environmental implications of their manufacturing and life cycles under different energy sources. All electrolyzer technologies employing low-carbon energy (nuclear, solar, or wind) exhibit life-cycle greenhouse gas (GHG) emissions of 0.3-2.4 kg-CO 2-eq /kg-H 2 . This is significantly lower than the corresponding GHG emissions for hydrogen production via both conventional steam methane reforming and alternative autothermal reforming with carbon capture and storage (by > 50%). The well-to-gate GHG emissions of low-carbon electrolyzers (0-0.36 kg-CO 2-eq / kg-H 2 ) qualify for Tier I of the production tax credit in the U.S.' Inflation Reduction Act of 2022, indicating their suitability for producing decarbonized hydrogen under this program.

08 HYDROGEN↗
DOE OSTI2024

Simple processing via thermal treatment and catalyst infiltration to enhance nickel electrode performance for liquid alkaline water electrolyzers

Two simple processes for enhancing liquid alkaline water electrolyzer performance are demonstrated. Both enhance 3D Ni electrodes by introducing a micron-scale rough structure throughout the bulk of the electrode. Oxidation/reduction relies on a simple thermal treatment cycle to create surface roughening through the volumetric expansion during NiO formation and volume contraction during reduction back to Ni metal. Catalyst infiltration introduces a washcoat of additional metal particles throughout the electrode, by flooding the electrode with catalyst precursor and converting it to micron-scale particles via a reducing thermal treatment. Further, the largest improvement in performance (211mV at 1.8Acm -2 ) is observed for infiltrated NiFe-3x catalyst. For Fe-free Ni-only electrodes, oxidation/reduction provides a larger improvement (157 mV at 1.8Acm -2 ) than infiltrated Ni-3X (106mV at 1.8Acm -2 ). For both processes, the observed electrode surface structure and performance is quite sensitive to the thermal treatment temperature.

08 HYDROGEN↗
DOE OSTI2024

Regulating the Third Metal to Design and Engineer Multilayered NiFeM (M: Co, Mn, and Cu) Nanofoam Anode Catalysts for Anion-Exchange Membrane Water Electrolyzers

In this study, alkaline anion-exchange membrane water electrolyzers (AEMWEs) for green hydrogen production have received intensive attention due to their feasibility of using earth-abundant platinum group metal (PGM)-free catalysts. Herein, the third metal is incorporated into NiFe-based catalysts to regulate their electronic structures and morphologies, aiming to achieve sufficient oxygen evolution reaction (OER) activity and performance in AEMWEs. The ternary NiFeM (M: Cu, Co, or Mn) catalysts are featured with multiple layered structures and nanofoam network morphologies, consisting of highly OER-active amorphous Ni-rich oxide shells and electrically conductive metallic alloy cores. The physical and electronic perturbations to the NiFe induced by a third element lead to a fine-tuning of the redox ability of the metal sites at the reaction centers, which breaks the scaling relationship between OH* and O* intermediates at the reaction centers. Thus, the unique structural configuration and electronic regulation simultaneously benefit catalytic activity and performance improvements. These NiFeM nanofoam catalysts demonstrated promising anode performance in actual AEMWEs, comparable to the IrO 2 reference, especially at high current densities. Notably, using various electrolytes (e.g., KOH solution or pure water) for AEMWEs exhibited a different performance trend among studied NiFeM catalysts, likely due to dynamic changes of catalysts under various OER environments.

25 ENERGY STORAGE↗
NASA NTRS1986

A photovoltaic-powered water electrolyzer - Its performance and economics

A prototype water electrolyzer designed to operate from a solar photovoltaic (PV) array without power conditioning was operated for three months at the Florida Solar Energy Center. A 1 kWpk PV array was used to operate the electrolyzer at internal gas pressure from 0 to 40 psig. Performance of the elecrolyzer/PV array was measured and characterized in terms of charge efficiency and power efficiency calculated from the operation data. The economics of residential production of hydrogen for energy purposes were calculated and summarized. While the near-term outlook for this energy storage technique was not found to be favorable, the long-term outlook was encouraging.

Hancock, O. G., Jr.↗
DOE OSTI2025

Reports from the Frontier: Understanding Voltage Losses in Anion Exchange Membrane Water Electrolyzers

With the growth of renewable energy sources, hydrogen is attracting significant attention worldwide as an effective medium for energy storage. “Green hydrogen” is currently produced primarily by water electrolysis in which water is split into hydrogen and oxygen using power from low-carbon energy sources such as wind, solar, and nuclear. Among the low temperature water electrolysis technologies, anion exchange membrane water electrolyzers (AEMWEs) have recently emerged as a promising competitor to traditional alkaline water electrolyzers (AWEs) and proton exchange membrane electrolyzers (PEMELs) due to their potential stack cost reduction in various cell components. In conclusion, favorable aspects of AEMWEs include the use of PGM-free electrocatalysts as well as low-cost membranes, bipolar plates (BPs), and porous transport layers while offering high voltage efficiency and durability.

08 HYDROGEN↗