(2026) Energy_Design, optimization, and life cycle assessment of anion exchange membrane electrolyzer using numerical methods

Chen W.-H.; Guo J.-Y.; Liang P.-C.; Lin C.-C.; Hsu F.-C.; Kwon E.E.

(Elsevier Ltd) Energy ISSN: 3605442 Vol.361 Issue. Article No.141998 DOI: 10.1016/j.energy.2026.141998

Efficient mass transfer in anion exchange membrane (AEM) electrolyzers is critical for enhancing hydrogen production. Current electrode designs often rely on single-layer porous transport layers (PTLs) or flow-field combinations, leaving the potential of multi-layer porous structures underexplored. This study develops a novel double-layer porous AEM electrolyzer featuring a unique anode design comprising two stacked nickel mesh layers with distinct porosities, unlike conventional configurations. Using numerical methods combined with the Taguchi method, five critical factors, including inlet flow rate, thickness ratio, upper- and lower-layer porosities, and operating temperature, are optimized to maximize performance. The results indicate that the maximum hydrogen production rate reaches 4.95 kg h⁻¹, with an energy consumption of 37 MJ (kg H₂)⁻¹. ANOVA results confirm that the inlet water flow rate accounts for over 80% of hydrogen production and pressure behavior. Life cycle assessment (LCA) shows that hydrogen compression and storage account for approximately 70% of the total carbon footprint, with an operational impact of 0.16 kg CO_2-eq·(kg H₂)⁻¹. This study provides a systematic framework for the design and sustainability evaluation of advanced AEM electrodes. © 2026 Elsevier Ltd. All rights are reserved, including those for text and data mining, AI training, and similar technologies.

This research was funded by financial support from the Bureau of Energy , Ministry of Economic Affairs , Taiwan, R.O.C., under grant number 115-B0401 .