The porous transport layer (PTL) in polymer electrolyte membrane (PEM) electrolyzers governs the overall efficiency. Its structural, thermal, and electronic properties determine how effortlessly the gases can be produced and can exit the PEM electrolyzer. In this study, we apply a stochastic reconstruction method for titanium felt-based PTLs to generate PTLs with different porosity, fiber radii, and anisotropy parameters. The morphology and topology of these PTLs are numerically characterized, and transport properties, such as gas diffusion coefficients and electrical and thermal conductivity, are computed via pore-scale modeling. Customized graded PTLs are proposed, exhibiting the optimal topology and bulk structure for the removal of gases, the conductance of electrons, and the transport of heat. The results indicate that the surface and transport properties of PTLs can be tailored by certain morphology parameters: PTLs with lower porosity and smaller fiber radii feature a more sufficient interfacial contact and superior electrical and thermal conductivity. Lowering the anisotropy parameters of PTLs results in a slight loss of interfacial contact but a substantial increase in the electrical and thermal conductivity in the through-plane direction. We outline that the design of PTLs should be differentiated depending on the operating conditions of electrolyzers. For nonstarvation conditions, PTLs should feature low porosity and small fiber radii, whereas for starvation conditions, PTLs should feature high porosity, low anisotropy parameters, and small fiber radii. Furthermore, graded PTLs with enhanced structural and transport properties can be developed by customizing the porosity, fiber radius, and fiber orientation.
Keywords: electrical conductivity; porous transport layer; thermal conductivity; topology; water electrolyzer.