Critical Current Density as a Performance Indicator for Gas-Evolving Electrochemical Devices

Reaching high current densities is absolutely imperative for electrochemical energy conversion, from fuel cells to CO2 reduction. Here, we identify the existence of a performance indicator for gas-evolving electrochemical energy conversion devices: the critical current density. The critical current density pinpoints a performance inflection point whereby both the gas saturations and mass transport overpotentials suddenly dominate cell performance and exacerbate failure. We elucidate the mass transport behavior of a polymer electrolyte membrane (PEM) water electrolyzer using in operando neutron imaging at operating current densities as high as 9 A ⋅ cm−2. Product gases become heterogeneously distributed in the porous transport layer adjacent to the catalyst layer and promote disastrous local hotspots. Turbulent reactant flows are prerequisites for mitigating these undesired mass transport overpotentials. Optimizing new materials and cell architectures with this performance indicator may unlock higher than previously reported performances for electrochemical energy conversion.