In Alkaline Electrolysis, what is the major factor limiting the maximum achievable current density?

In Alkaline Electrolysis, the major factor limiting the maximum achievable current density is bubble formation and its impact on ionic conductivity within the electrolyte. Alkaline Electrolysis is a process that uses an alkaline electrolyte, such as potassium hydroxide (KOH) or sodium hydroxide (NaOH) solution, to split water into hydrogen and oxygen using electricity. As the electrolysis reaction proceeds, hydrogen gas is generated at the cathode (negative electrode) and oxygen gas is generated at the anode (positive electrode). These gases form bubbles on the electrode surfaces. These bubbles reduce the effective surface area available for the electrochemical reaction, as they block the access of electrolyte ions to the electrode surface. Furthermore, the bubbles increase the electrical resistance of the electrolyte, as they displace the conductive electrolyte solution. This increased resistance reduces the ionic conductivity, making it more difficult for ions to move between the electrodes and sustain a high current density. While other factors, such as electrode kinetics and mass transport limitations, also play a role, bubble formation is the most significant impediment to achieving high current densities in alkaline electrolyzers. Techniques to mitigate bubble formation, such as using advanced electrode materials with improved bubble detachment properties or employing forced electrolyte circulation, are crucial for enhancing the performance of alkaline electrolysis systems.