Nickel Fiber Felt for Hydrogen Electrolyzers | AEM Gas Diffusion Layer Ni Paper Felts

Description

Nickel Fiber Felt in Hydrogen Electrolyzers

Role as Gas Diffusion Layer (GDL)

• Enhanced Mass Transfer: 3D porous structure (80-95% porosity) ensures uniform gas/liquid flow, reducing voltage drop.
• High Current Density Support: Stable performance under >2 A/cm², critical for industrial-scale electrolysis.
• Corrosion Resistance: Withstands acidic/alkaline electrolytes (pH 1-14), prolonging electrolyzer lifespan.

Key Material Parameters

1. Optimized Physical & Chemical Properties

Parameter	Specifications	Industry Impact
Porosity	50-95% (adjustable)	Facilitates rapid gas/liquid diffusion, reducing voltage losses.
Fiber Diameter	5-20 μm (controlled distribution)	Balances mechanical strength and surface area for catalysis.
Thickness	0.5-3.0 mm (customizable)	Adapts to compact electrolyzer stack designs.
Electrical Conductivity	>500 S/cm (at 25°C)	Minimizes interfacial resistance for high current density (>2 A/cm²).
Thermal Stability	Stable up to 800°C (in inert atmosphere)	Compatible with SOEC high-temperature operations.
Corrosion Resistance	pH 1-14 (acid/alkali environments)	20,000+ hours lifespan in PEM/AWE electrolyzers.

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How Nickel Fiber Felts Work Inside Hydrogen Electrolyzers

1. Role in PEM Electrolyzers (Proton Exchange Membrane)

• Location: Sandwiched between the catalyst-coated membrane (CCM) and bipolar plates.
• Core Functions:
  • Gas Diffusion: 3D porous structure ensures uniform H₂/O₂ distribution, preventing bubble coalescence (target pore size: 50-200 μm).
  • Electron Conduction: Directly transfers electrons from the catalyst layer to the current collector.
  • Water Management: Hydrophilic/hydrophobic treatment options regulate water retention for stable membrane hydration.

2. Application in Alkaline Water Electrolyzers (ALK)

• Replaces Titanium Meshes: Nickel fiber felts reduce material costs by 40% while maintaining performance in 30% KOH solutions.
• Structure:
  • Anode Side: Nickel felt with IrO₂ coating (overpotential <300 mV @ 1 A/cm²).
  • Cathode Side: Nickel felt with Ni-Mo alloy coating for HER (hydrogen evolution reaction) optimization.

3. High-Temperature Performance in SOEC (Solid Oxide Electrolyzers)

• Operating Conditions: 700-800°C, steam/CO₂ co-electrolysis.
• Design Advantages:
  • Sintering Resistance: Maintains porosity >85% after 5,000 thermal cycles.
  • Interconnect Compatibility: Matches thermal expansion coefficient (12-14 ×10⁻⁶/K) with YSZ electrolytes.

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Technical Advantages of Jiahong’s Nickel Fiber Felts

1. Precision Engineering for Electrolyzer Optimization

• Pore Structure Control: Computational fluid dynamics (CFD) modeling tailors pore size gradients to target gas flux (e.g., 0.2-1.5 mL/cm²·s).
• Surface Treatments:
  • Plasma Spraying: Adds catalytic layers (e.g., Pt, NiFe-LDH) for enhanced reaction kinetics.
  • Hydrophobic Coating: PTFE treatment for PEM electrolyzer water management.

2. Performance Validation

• Accelerated Stress Tests:
  • 1,000-hour cyclic polarization (0.5-2.5 A/cm²) with <5% conductivity loss.
  • ASTM G61 corrosion testing in simulated PEM (0.5M H₂SO₄, 80°C) and AWE (6M KOH, 90°C) environments.

FAQ Section

Q: Can nickel fiber felts replace conventional carbon paper in PEM electrolyzers?
A: Yes. Our nickel felts offer 3x higher corrosion resistance and 30% lower contact resistance compared to carbon-based GDLs.

Q: How is porosity measured for electrolyzer applications?
A: We use mercury intrusion porosimetry (ASTM D4404) and micro-CT scanning to ensure pore uniformity (SD <5%).