International Journal of Hydrogen Energy, cilt.224, 2026 (SCI-Expanded, Scopus)
Hydrogen generation by chlor-alkali electrolysis is a promising method for combining industrial chlorine generation with sustainable hydrogen production. In this research, the performance of hydrogen generation was compared utilizing two easily accessible membrane forms, Nafion 117 (N117) and Nafion 212 (N212), in a membrane-based chlor-alkali electrolysis. To clarify the membrane-dependent electrochemical behavior, the two membranes were evaluated under different working voltages (5, 7.5, and 10 V) and temperatures (20 °C and 45 °C) using NaCl, KCl, CaCl2, and MgCl2 as electrolytes. The findings show that membrane structure influences hydrogen generation kinetics, current density, and energy performance. In monovalent electrolytes (NaCl and KCl), the N212 membrane consistently showed faster hydrogen generation kinetics and higher energy efficiency than the N117 membrane, owing to its thinner design and lower ionic resistance. Under these conditions, increasing the temperature improved hydrogen generation across the two membranes. Electrolytes with divalent cations (CaCl2 and MgCl2) elicited different membrane-specific responses. The N212 membrane produced hydrogen efficiently in CaCl2 at high temperatures and voltages, but struggled in MgCl2 due to greater membrane-ion interactions. Under such circumstances, the thicker N117 membrane exhibited relatively more stable electrochemical activity. The N212 membrane demonstrated good ion selectivity at a 5V applied voltage and 45 °C inlet temperature, achieving its highest hydrogen generation performance of 26.8% in NaCl solution and its lowest performance of 5.5% in MgCl2 solution. Overall, this study demonstrates that hydrogen generation performance in chlor-alkali electrolysis is strongly governed by membrane properties and electrolyte composition, providing practical guidance for membrane selection and system optimization in hydrogen-producing chlor-alkali processes.