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Gas crossover in Polyphenylene Sulfide (PPS)-based separators (often used as fabric or felt in AWE) is primarily driven by their porosity, with hydrogen crossover typically ranging from 0.04% to 0.16% for diaphragms, depending on pressure and structure. While PPS provides excellent chemical stability and hydrophilicity when modified (e.g., with ZrO
), high porosity can cause significant gas crossover, making structural optimization or composite, dense approaches necessary to manage leakage, particularly at low current densities.
Key Aspects of PPS Membrane Gas Crossover
- Permeability and Structure: PPS diaphragms (often composites like Zirfon) generally show hydrogen permeability around 1.2 to 20 .
- Performance Trade-offs: Highly porous PPS felts provide low ohmic resistance but increase gas crossover risk when pressure differences exist.
- Advanced Modifications: Modifying PPS with hydrophilic fillers like Zirconium dioxide () can enhance wettability and reduce bubble transport, improving safety against high gas crossover.
- Operating Limitations: Gas crossover (specifically in) is the limiting factor for operating at low loads (low current density), with systems designed to keep impurities below 2% to avoid explosion limits.
To ensure safety, the international standard for hydrogen production using water electrolysis has established a maximum allowable
impurity in the
gas stream of 2.0 vol%.
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Gas Crossover Rate in ALK Electrolysis PPS Membrane
Hfsinopower.com
https://www.hfsinopower.com › gas-crossover-rate-in-alk...
Hfsinopower.com
https://www.hfsinopower.com › gas-crossover-rate-in-alk...
Customized Gas Crossover Rate In ALK Electrolysis PPS Membrane at factory price from Hfsinopower ... Gas Crossover Rate in ALK Electrolysis PPS Membrane.Read more
Hydrogen crossover in proton exchange membrane water ...
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
by Y Zhao2026 — In contrast, the composite membranes HPM-2080-X and HPM-20100-WX demonstrated superior performance with remarkably low crossover rates of 1.44% ...Read more
Separators and Membranes for Advanced Alkaline Water ...
ACS Publications
https://pubs.acs.org › doi
ACS Publications
https://pubs.acs.org › doi
by D Henkensmeier2024Cited by 269 — (35) High porosity of PPS needle felt separators results in excellent ion conductivity thereof, but leads to a significant gas crossover. These ...Read more
Separators and Membranes for Advanced Alkaline Water ...
PubMed Central (PMC) (.gov)
https://pmc.ncbi.nlm.nih.gov › articles › PMC11117188
PubMed Central (PMC) (.gov)
https://pmc.ncbi.nlm.nih.gov › articles › PMC11117188
by D Henkensmeier2024Cited by 266 — High porosity of PPS needle felt separators results in excellent ion conductivity thereof, but leads to a significant gas crossover. These separators can be ...Read more
Sulfonated‐PPS/LDH Composite Membrane With ...
Wiley Online Library
https://onlinelibrary.wiley.com › doi › smll
Wiley Online Library
https://onlinelibrary.wiley.com › doi › smll
7 days ago — An ideal membrane must simultaneously prevent gas crossover, ensure ionic conductivity, and withstand harsh alkaline conditions. Yet ...Read more
Gas Crossover in Alkaline Water Electrolysis
Eindhoven University of Technology
https://research.tue.nl › files › MCE_afstudeerver...
Eindhoven University of Technology
https://research.tue.nl › files › MCE_afstudeerver...
PDF
by JT KraakmanCited by 3 — In contrast, with a differential pressure of 0.3 bar, the gas crossover rates were in line with the difference in diaphragm permeability K, ...Read more
Innovative membrane with selective gas permeability for ...
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
by AA Haleem2023Cited by 22 — A new membrane selectively permeates gases in alkaline water electrolysis. The membrane orientation versus electrodes influences gas purity.Read more
Advancing Membrane Materials for Alkaline Water ...
Iranian Journal of Chemistry and Chemical Engineering (IJCCE)
https://www.ijcce.ac.ir › ...
Iranian Journal of Chemistry and Chemical Engineering (IJCCE)
https://www.ijcce.ac.ir › ...
PDF
by A Kanbetov2026 — Based on this, one would expect ten times higher gas crossover rates when the membrane is soaked 10% with electrolyte and 90% gas. As a ...Read more
A rationally thin composite membrane with differentiated ...
Nature
https://www.nature.com › ... › articles
Nature
https://www.nature.com › ... › articles
by J You2025Cited by 17 — The prepared composite membrane shows better electrolytic performance (1.71 V at 1 A cm−2) and stability (working for 6352 h). In addition, an ...Read more
A Conceptual Approach to Reduce the Product Gas ...
MDPI
https://www.mdpi.com › ...
MDPI
https://www.mdpi.com › ...
by DL Martinho2025Cited by 4 — The results suggest that an increase in bubble diameter from 50 microns to 150 microns results in a 10% higher current density at a cell voltage of 2.1 V.Read more