CFD-Based Flow Field Optimization for High-Performance Anion Exchange Membrane Electrolyzers

The growing demand for sustainable energy solutions has increased the focus on hydrogen's role as a clean and renewable energy source. Hydrogen production through anion exchange membrane (AEM) electrolysis offers considerable advantages over traditional methods, such as lower reliance on costly precious metal catalysts and enhanced durability in alkaline environments. This study optimized AEM electrolyzer performance through computational fluid dynamics simulations, analyzing the effects of flow field parameters, diffusion layer properties, and channel geometries. The simulation results reveal that the diffusion layer thickness (1.6–2.44 mm) and porosity (0.2–0.9) substantially affect flow distribution and pressure drop, with a thinner mesh resulting in higher flow velocities near the electrode surface and a lower pressure drop, respectively. A nickel mesh improves flow uniformity but increases pressure drop, requiring a careful balance between efficiency and energy consumption. An optimized parameter combination (diffusion angle = 70°, inlet velocity = 0.3 LPM, and diffusion layer thickness = 1.92 mm) identified through response surface methodology and the genetic algorithm resulted in a 20% performance improvement over the baseline design. This research provides valuable insights into the design of AEM electrolyzers, supporting their development as a cornerstone technology for green hydrogen production.