Performance optimization of PEM electrolyzers: An experimental and Taguchi-based approach

In this study, the performance of a proton exchange membrane (PEM) water electrolyzer with an active area of 9 cm² was investigated under various operating conditions. At the anode, a three-layer titanium cross-mesh along with a fiber felt structure is employed. A total of twenty-seven experiments are conducted according to Taguchi's design of experiments to investigate extremes of operating temperature (40 °C, 60 °C, 80 °C), clamping torque (5 Nm, 7 Nm, 10 Nm), and water flow rates (10, 20, 30 mL/min) on hydrogen production and current density. From these experiments, it was noticed that temperature has the most notable influence by enhancing reaction kinetics and membrane conductivity. Clamping torque improves the electrode-membrane contacts and reduces internal resistance. Water flow rates have an effect on membrane hydration and gas removal, although somewhat less so. The three-layer mesh structure enables effective water distribution and gas evacuation, leading to lower overvoltage and steady operation. The best results came at 80 °C, torque of 10 Nm, and flow rate of 10 mL/min. Thus, the findings emphasize the dominant role of temperature and show that clamping torque should not only be regarded as a mechanical factor but also as an electrochemically active design factor in PEM electrolyzer design.