Strategies for industrial-grade seawater electrolysis: from electrocatalysts and device design to techno-economic analysis

Abstract

Seawater electrolysis offers a promising route for sustainable hydrogen production, utilizing abundant seawater to meet global energy demands while addressing environmental concerns. However, challenges such as inefficiencies, high costs, and reliance on noble metal catalysts hinder its practical implementation. This review examines the fundamental mechanisms of seawater electrolysis, focusing on the hydrogen and oxygen evolution reactions (HER and OER) at industrial-scale current densities. Key strategies for catalyst design, including interfacial engineering, structural optimization, and improved mass and electron transport, to enhance efficiency and stability are discussed. Additionally, device architecture and techno-economic considerations are explored to facilitate scalable, cost-effective deployment. By providing insights into advanced materials and system innovations, this review outlines pathways for integrating seawater electrolysis into large-scale sustainable energy solutions.