Abstract
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 detachment of oxygen and hydrogen bubbles. The findings indicate that the optimal design and location of the baffles improve fluid mixing and enhance bubble detachment, resulting in a more uniform electrolyte distribution and decreased concentration polarization. Several key performance 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 electrolyzers, aiming to enhance efficiency and operational robustness.