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Review

Proton Exchange Membrane Electrolysis Revisited: Advancements, Challenges, and Two-Phase Transport Insights in Materials and Modelling

by
Ali Bayat
1,
Prodip K. Das
2,
Goutam Saha
1,3,4,* and
Suvash C. Saha
1,*
1
School of Mechanical and Mechatronic Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia
2
School of Engineering, The University of Edinburgh, Edinburgh EH9 3BF, UK
3
Miyan Research Institute, International University of Business Agriculture and Technology, Dhaka 1230, Bangladesh
4
Department of Mathematics, University of Dhaka, Dhaka 1000, Bangladesh
*
Authors to whom correspondence should be addressed.
Submission received: 10 March 2025 / Revised: 27 March 2025 / Accepted: 2 April 2025 / Published: 4 April 2025

Abstract

The transition to clean energy has accelerated the pursuit of hydrogen as a sustainable fuel. Among various production methods, proton exchange membrane electrolysis cells (PEMECs) stand out due to their ability to generate ultra-pure hydrogen with efficiencies exceeding 80% and current densities reaching 2 A/cm2. Their compact design and rapid response to dynamic energy inputs make them ideal for integration with renewable energy sources. This review provides a comprehensive assessment of PEMEC technology, covering key internal components, system configurations, and efficiency improvements. The role of catalyst optimization, membrane advancements, and electrode architectures in enhancing performance is critically analyzed. Additionally, we examine state-of-the-art numerical modelling, comparing zero-dimensional to three-dimensional simulations and single-phase to two-phase flow dynamics. The impact of oxygen evolution and bubble dynamics on mass transport and performance is highlighted. Recent studies indicate that optimized electrode architectures can enhance mass transport efficiency by up to 20%, significantly improving PEMEC operation. Advancements in two-phase flow simulations are crucial for capturing multiphase transport effects, such as phase separation, electrolyte transport, and membrane hydration. However, challenges persist, including high catalyst costs, durability concerns, and scalable system designs. To address these, this review explores non-precious metal catalysts, nanostructured membranes, and machine-learning-assisted simulations, which have demonstrated cost reductions of up to 50% while maintaining electrochemical performance. Future research should integrate experimental validation with computational modelling to improve predictive accuracy and real-world performance. Addressing system control strategies for stable PEMEC operation under variable renewable energy conditions is essential for large-scale deployment. This review serves as a roadmap for future research, guiding the development of more efficient, durable, and economically viable PEM electrolyzers for green hydrogen production.
Keywords: PEM electrolysis; hydrogen production; multiphysics modelling; catalyst development; renewable energy; numerical simulation PEM electrolysis; hydrogen production; multiphysics modelling; catalyst development; renewable energy; numerical simulation

Share and Cite

MDPI and ACS Style

Bayat, A.; Das, P.K.; Saha, G.; Saha, S.C. Proton Exchange Membrane Electrolysis Revisited: Advancements, Challenges, and Two-Phase Transport Insights in Materials and Modelling. Eng 2025, 6, 72. https://doi.org/10.3390/eng6040072

AMA Style

Bayat A, Das PK, Saha G, Saha SC. Proton Exchange Membrane Electrolysis Revisited: Advancements, Challenges, and Two-Phase Transport Insights in Materials and Modelling. Eng. 2025; 6(4):72. https://doi.org/10.3390/eng6040072

Chicago/Turabian Style

Bayat, Ali, Prodip K. Das, Goutam Saha, and Suvash C. Saha. 2025. "Proton Exchange Membrane Electrolysis Revisited: Advancements, Challenges, and Two-Phase Transport Insights in Materials and Modelling" Eng 6, no. 4: 72. https://doi.org/10.3390/eng6040072

APA Style

Bayat, A., Das, P. K., Saha, G., & Saha, S. C. (2025). Proton Exchange Membrane Electrolysis Revisited: Advancements, Challenges, and Two-Phase Transport Insights in Materials and Modelling. Eng, 6(4), 72. https://doi.org/10.3390/eng6040072

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