CFD-based optimal design of a portable and stackable alkaline water electrolyser for hydrogen production

Hydrogen is increasingly recognized as a vital energy carrier for a sustainable future. Among the various methods for hydrogen production, alkaline water electrolysis (AWE) stands out as a well- established and commercially viable option. However, their more effective deployment requires more advanced, portable, and scalable designs. This study explores systematic model-based shape optimization of the next generation AWE based on computational fluid dynamic (CFD) aimed to enhance the hydrodynamics and electrochemical performance. Several design geometries and arrangements were proposed including flow baffles to enhance hydrodynamic and facilitate de- tachment of oxygen and hydrogen bubbles. The findings indicate that the optimal design and lo- cation of the baffles improve fluid mixing and enhance bubble detachment, resulting in a more uniform electrolyte distribution and decreased concentration polarization. Several key perfor- mance indicators were considered to analyse the performance of proposed designs including gas production rates, polarization curves, and fluid flow velocity profiles. The insights gained from this research offer valuable recommendations for optimizing flow field designs in alkaline water elec- trolyzers, aiming to enhance efficiency and operational robustness.