One-pot synthesis of FeNi3/FeNiOx nanoparticles for PGM-free anion exchange membrane water electrolysis

Low-temperature anion exchange membrane water electrolysis (AEMWE) is one of the most promising technologies to produce green hydrogen. To date, membrane-electrode assembly (MEA) based on platinum group metal (PGM) electrocatalysts shows higher performance than PGM-free ones. Here, a single and easy synthesis for non-noble metal electrocatalysts (PGM-free) for both hydrogen and oxygen evolution reactions (HER and OER) was developed. Both electrocatalysts consist of FeNi3/FeNiOx nanoparticles obtained through chemical reduction using hydrazine. The electrocatalyst exhibits an overpotential of 210 mV and 234 mV for HER and OER respectively, at a current density of 10 mA cm−2 in 1 M KOH electrolyte, allowing a comparison between mass activity and geometric activity compared to PGM catalysts. In addition to a preliminary electrochemical characterization of the FeNi3/FeNiOx, the electrocatalyst were integrated into a pilot-scale AEMWE at both anode and cathode, which reaches (without iR-correction) 1.72 V and 1.94 V at a current density of 0.4 A cm−2 and 1 A cm−2 respectively at 60 °C. This PGM-free MEA outperforms the one based on Pt/C at cathode and RuO2 at anode with a voltage gap of 284 mV at 1 A cm−2. The aforementioned MEA was tested for 150 h with a discontinuous power profile, in order to get an idea of the possible degradation trends for a future industrial application, the reversible and irreversible voltage losses were calculated resulting in a degradation rate of 886 µV/h. This work demonstrates a simple and scalable synthesis of earth-abundant electrocatalytic materials for high-efficiency AEM water electrolysis.