Ultrasonic Spraying PEM Electrolysis for Hydrogen Production

Ultrasonic spraying PEM electrolysis for hydrogen production: Breaking through tradition and revolutionizing the future

During the critical period of global energy transition, PEM electrolysis of water for hydrogen production technology has become the focus of the hydrogen energy field due to its high purity and efficiency. This technology achieves water electrolysis through proton exchange membranes, demonstrating great potential in the field of clean energy. Cheersonic’s ultrasonic spraying technology is bringing a new process revolution to PEM electrolysis of water for hydrogen production, significantly improving the performance of core components and system efficiency.

1. The core principle and structure of PEM electrolysis for hydrogen production from water
PEM electrolysis of water for hydrogen production is based on electrochemical processes, with the core component being the proton exchange membrane. At the anode, water molecules undergo oxidation reaction: H2O − 2e − → 21 O2 ↑+2H+, and the generated oxygen escapes. Protons migrate to the cathode through the exchange membrane. At the cathode, protons combine with electrons to undergo a reduction reaction: 2H++2e − → H2 ↑, achieving the decomposition of water into hydrogen and oxygen.

Proton exchange membranes, as the core technology, are usually composed of high molecular weight polymers, such as perfluorosulfonic acid membranes, which achieve proton conduction through sulfonic acid groups. Its performance directly affects hydrogen production efficiency and requires high proton conductivity, chemical stability, and mechanical strength to ensure efficient proton transport, resist strong oxidative environments, and maintain structural integrity.

The electrode material is the key factor determining the reaction efficiency. Iridium (Ir) and its oxides are commonly used as anodes to reduce the overpotential of oxygen evolution reactions; The cathode is mainly composed of platinum (Pt) and its alloys, which promote hydrogen evolution reaction. However, the high cost and scarcity of precious metals limit the large-scale application of technology.

2. The innovative application of ultrasonic spraying technology

• Optimization of proton exchange membrane coating
  Ultrasonic spraying technology atomizes the solution into uniform and fine droplets through high-frequency vibration, and accurately sprays them onto the surface of the proton exchange membrane. This process can form ultra-thin and uniform functional coatings on the membrane surface, significantly improving proton conductivity. Compared with traditional coating methods, the droplet distribution of ultrasonic spraying is more uniform, which can avoid defects such as uneven thickness and pores on the membrane surface, and improve proton conduction efficiency by 15% -20%. Meanwhile, the uniformity of the coating helps to enhance the chemical stability of the membrane, prolong its service life, and reduce maintenance costs caused by membrane performance degradation.
• Preparation of electrode catalyst layer
  Ultrasonic spraying technology has demonstrated unique advantages in the preparation of electrode catalyst layers. Traditional coating methods can easily lead to catalyst aggregation and uneven distribution, affecting catalytic activity. Ultrasonic spraying can atomize the catalyst solution into nano-sized droplets, evenly covering the electrode surface, making the catalyst loading more precise and the distribution of active sites more uniform. Experimental data shows that electrodes prepared by ultrasonic spraying can reduce the overpotential of oxygen evolution reaction (OER) and hydrogen evolution reaction (HER) by 10% -15%, effectively improving electrolysis efficiency and reducing electricity consumption. In addition, this technology can accurately control the coating thickness, avoid catalyst waste, reduce the use of precious metals, and alleviate cost pressure.
• Bipolar plate surface treatment
  As an important component of electrolytic cells, the surface properties of bipolar plates directly affect gas transport and conductivity. Ultrasonic spraying can form ultra-thin corrosion-resistant coatings or conductive enhancement layers on the surface of bipolar plates. By optimizing the coating structure, the contact resistance between the bipolar plate and the membrane electrode can be reduced, the gas diffusion efficiency can be improved, the internal losses of the system can be reduced, and the overall performance of the hydrogen production system can be further improved.

3. The significant advantages of ultrasonic spraying technology

• High precision and high uniformity
  The nanoscale droplet atomization technology of ultrasonic spraying ensures that the coating thickness error is controlled within ± 5nm, and the uniformity of the film layer is improved by more than 30%. This high-precision coating preparation capability can fully leverage the performance advantages of proton exchange membranes and electrode materials, reducing efficiency losses caused by coating defects.
• Significant increase in material utilization rate
  The traditional coating method has serious problems of material splashing and waste, while ultrasonic spraying can increase material utilization from 60% to over 90% by accurately controlling the direction and flow rate of droplet spraying. Especially when using precious metal catalysts, this technology can significantly reduce material costs and alleviate the high cost pressure of PEM water electrolysis hydrogen production systems.
• Strong process flexibility
  Ultrasonic spraying technology can adapt to various material systems, whether it is polymer solutions, metal oxide slurries, or precious metal catalysts, all of which can achieve high-quality coating. At the same time, this technology is applicable to components of different sizes and shapes, which can meet the diverse needs of laboratory research and industrial large-scale production, and provide strong support for the rapid iteration and industrialization promotion of technology.

4. Current situation and prospects of hydrogen production by PEM electrolysis of water
Although PEM electrolysis hydrogen production technology has significant advantages such as high hydrogen purity and fast response speed, high cost and strict water quality requirements are still the main bottlenecks. The introduction of ultrasonic spraying technology provides a new path to overcome these challenges. By optimizing the performance of core components and reducing material losses, this technology can effectively improve system efficiency, reduce operating costs, and promote the large-scale commercialization of PEM water electrolysis hydrogen production.

In the future, with the deep integration of ultrasonic spraying technology and PEM electrolysis for hydrogen production, as well as breakthroughs in the research and development of low-cost alternative materials, this technology is expected to play a greater role in renewable energy storage, fuel cell vehicles, and other fields, becoming a key supporting technology for global energy transformation and helping to achieve carbon neutrality goals.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

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