Performance Optimization of a Novel Dry-Cell Electrolyzer for Green Hydrogen Production via Response Surface Methodology

Mustafa, Hassan M. M.; Abd-Elghany, Mohamed K.; Ibrahim, Abdelrhman A.; Elwesif, M. Abd-Ellfatah; Hosny, Abd El-Rahman A.; Mohamaden, Abdallah A.; Soliman, Omar A. Soliman; Khalifa, Moustafa S.; .El-Hadidy, Sherihan; Ghaly, Montaser youssry; Mohamed, R. M.

doi:10.21608/ejchem.2025.385921.11781

	Performance Optimization of a Novel Dry-Cell Electrolyzer for Green Hydrogen Production via Response Surface Methodology
Egyptian Journal of Chemistry
Articles in Press, Accepted Manuscript, Available Online from 27 July 2025
Document Type: Original Article
DOI: 10.21608/ejchem.2025.385921.11781
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Authors
Hassan M. M. Mustafa ¹; Mohamed K. Abd-Elghany²; Abdelrhman A. Ibrahim³; M. Abd-Ellfatah Elwesif²; Abd El-Rahman A. Hosny²; Abdallah A. Mohamaden²; Omar A. Soliman Soliman²; Moustafa S. Khalifa²; Sherihan .El-Hadidy⁴; Montaser youssry Ghaly⁵; R. M. Mohamed ⁶
¹Mechanical Engineering Department, Engineering and Renewable Energy Research Institute, National Research Centre, Giza, Egypt.
²Chemical Engineering Department, Canal High Institute of Engineering & Technology
³Chemical Engineering Department, Canal High Institute of Engineering &Technology
⁴Basic Sciences Department, Canal High Institute of Engineering and Technology, Suez, Egypt.
⁵National Research Center - Chemical Engineering and Pilot Department - Cairo, Egypt
⁶chemical engineering department, Canal High Institute of Engineering and Technology
Abstract
In response to the intensifying global energy crisis and the urgent need to mitigate carbon emissions associated with fossil fuel combustion, the development of efficient, low-carbon hydrogen production technologies has become a critical research priority. Among available methods, water electrolysis powered by renewable energy offers a promising pathway to green hydrogen. However, conventional wet-cell designs often suffer from limited scalability, high material costs, and operational inefficiencies. This study presents the design, experimental validation, and multi-variable optimization of an innovative dry-cell electrolysis system employing corrosion-resistant and cost-effective 316L stainless steel electrodes. The system architecture emphasizes modularity, compactness, and enhanced gas separation efficiency—key attributes for industrial deployment. To systematically optimize hydrogen generation performance, Response Surface Methodology was applied to evaluate the interactive effects of applied voltage, electrolyte concentration (NaOH wt.%), and electric current on hydrogen flow rate and energy consumption. Under optimal operating conditions (14 Volt, 0.95 Ampere, and 0.1 wt.% NaOH), the system achieved a peak hydrogen production rate of 48 mL/s, demonstrating a substantial improvement over comparable baseline systems reported in the literature. While hydrogen output was quantified volumetrically, direct gas purity analysis using gas chromatography or sensors was not conducted; this represents a limitation that will be addressed in future work through comprehensive quantitative purity assessments. These results confirm the dry-cell design’s potential to deliver high-yield, energy-efficient hydrogen production using affordable and durable materials, offering a scalable solution aligned with global decarbonization strategies and the United Nations Sustainable Development Goals.
Keywords
Dry-cell Electrolyzer; sustainable energy; hydrogen production; response surface methodology; stainless steel electrodes


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