Recent advances in catalysts and interface engineering for high-performance proton exchange membrane water electrolyzers

IF 31.6 1区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials Science and Engineering: R: Reports Pub Date : 2025-09-30 DOI:10.1016/j.mser.2025.101124

Muhammad Arshad , Akbar Bashir , Haseebul Hassan , Shuiping Luo , Muhammad Bilal , Muhammad Wasim , Wen Chen , Lei Xie , Jing-Li Luo , Xian-Zhu Fu

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引用次数: 0

Abstract

Proton exchange membrane (PEM) water electrolysis has emerged as the most promising technology for sustainable hydrogen production, enabling the decarbonization of energy systems and hard-to-abate industrial sectors. This comprehensive review critically examines recent breakthroughs and persistent challenges across the entire PEMWE value chain, from advanced materials to system integration and large-scale deployment. We present a detailed analysis of cutting-edge developments in electrocatalysts, including atomically dispersed Ir/Ru oxides, high-entropy alloys, and non-precious metal alternatives that achieve superior activity and stability while reducing noble metal loadings to ≤ 0.1 mg cm⁻². This study systematically evaluates advanced membrane innovations, including ultrathin reinforced perfluorosulfonic acid (PFSA) and hydrocarbon-based alternatives, which achieve simultaneous high proton conductivity and exceptional mechanical durability. A special focus is placed on engineering solutions for porous transport layers and bipolar plates that address critical mass transport limitations at high current densities (≥ 3.0 A cm⁻²). Beyond component-level advances, we analyse system integration strategies, including dynamic operation (0–200 % rated power), hybrid renewable energy coupling, and high-pressure electrolysis (up to 100 bar), that enhance efficiency and economic viability. We provide a critical assessment of key technological barriers, including membrane degradation mechanisms, catalyst dissolution pathways, and the iridium supply chain crisis, while proposing mitigation strategies through advanced manufacturing and alternative approaches. By integrating fundamental research with industrial perspectives, we present a deployment roadmap that underscores the essential interplay of materials innovation, policy frameworks, and market mechanisms to unlock PEMWE’s potential for the global energy transition.

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高性能质子交换膜水电解槽催化剂及界面工程研究进展

质子交换膜（PEM）电解已成为最有前途的可持续制氢技术，使能源系统脱碳和难以减排的工业部门成为可能。这篇全面的综述严格审查了整个PEMWE价值链的最新突破和持续挑战，从先进材料到系统集成和大规模部署。我们详细分析了电催化剂的最新发展，包括原子分散的Ir/Ru氧化物、高熵合金和非贵金属替代品，这些替代品在将贵金属负载降低到≤ 0.1 mg cm−2的同时，实现了卓越的活性和稳定性。这项研究系统地评估了先进的膜创新，包括超薄增强全氟磺酸（PFSA）和碳氢化合物基替代品，它们同时实现了高质子导电性和卓越的机械耐久性。特别关注多孔传输层和双极板的工程解决方案，以解决高电流密度（≥3.0 A cm−2）下的临界质量传输限制。除了组件级的进步，我们还分析了系统集成策略，包括动态操作（0-200 %额定功率），混合可再生能源耦合和高压电解（高达100 bar），这些策略提高了效率和经济可行性。我们对关键技术障碍进行了关键评估，包括膜降解机制、催化剂溶解途径和铱供应链危机，同时提出了通过先进制造和替代方法缓解战略。通过将基础研究与工业观点相结合，我们提出了一个部署路线图，强调了材料创新、政策框架和市场机制之间的基本相互作用，以释放PEMWE在全球能源转型中的潜力。

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来源期刊

Materials Science and Engineering: R: Reports 工程技术-材料科学：综合

CiteScore

60.50

自引率

0.30%

发文量

审稿时长

34 days

期刊介绍： Materials Science & Engineering R: Reports is a journal that covers a wide range of topics in the field of materials science and engineering. It publishes both experimental and theoretical research papers, providing background information and critical assessments on various topics. The journal aims to publish high-quality and novel research papers and reviews. The subject areas covered by the journal include Materials Science (General), Electronic Materials, Optical Materials, and Magnetic Materials. In addition to regular issues, the journal also publishes special issues on key themes in the field of materials science, including Energy Materials, Materials for Health, Materials Discovery, Innovation for High Value Manufacturing, and Sustainable Materials development.