Electrodes modified with Ni electrodeposition decrease hexavalent chromium generation in an alkaline electrolysis process

Abstract Alkaline water electrolysis is one of the easiest methods used to produce hydrogen, offering the advantages of simplicity and low cost. The challenges for the widespread use of water electrolysis are to reduce energy consumption, cost and maintenance and to increase the reliability, durability and safety of the process. The alkaline electrolysis of water has been used for many years to obtain H2 and O2; however, less expensive, more active, endurable and efficient electrodes must be designed. Stainless steel (SS) is considered one of the least expensive electrode materials for alkaline electrolysers, since it is relatively chemically stable and has a low overpotential. Nevertheless, SS anodes do not withstand high concentration alkaline solutions because they undergo a corrosion process. If the electrolyser operates at a voltage of up to 1.6 V, it can generate Fe3O4 and hazardous hexavalent chromium (Cr6+) at the anode. Hexavalent chromium is generated when the chromium-containing stainless steel electrodes undergo an electro-oxidation process. In this work, a low power alkaline electrolyser was designed. In the first step, six electrodes were manufactured of stainless steel. In the second step, a nickel layer with matte or opaque finish was deposited on the SS surfaces to improve their resistance to corrosion and wear. Then, the performance curves and the production of hexavalent chromium were determined. The performance curve after 70 h of operation with nickel-plated electrodes showed an overpotential of 0.5 V at 10 A compared with stainless steel electrodes. Cr6+ was detected in the electrolyte and bubbler water of the system using SS electrodes at values that exceeded the standard (>0.5–1 mg L−1). If the electrolyser used Ni-electrodeposited electrodes, Cr6+ was observed in quantities within the normal range (