From laboratory to industrial scale: nickel-based catalysts for hydrogen evolution under highcurrent–density alkaline electrolysis

The global energy crisis and the growing demand for sustainable energy sources have driven considerable interest in green hydrogen production via water electrolysis. Among non-noble metal catalysts, nickel-based materials have emerged as promising candidates for the hydrogen evolution reaction (HER) in alkaline media, owing to their natural abundance and intrinsic catalytic activity. However, their practical application remains hindered by poor stability under high current densities, challenges in regulating active site distribution, and obstacles to large-scale implementation. This review systematically explores the fundamental principles of alkaline water electrolysis (AWE) and alkaline anion exchange membrane water electrolysis (AEMWE), critically assesses the key barriers to commercialization of nickel-based catalysts, and discusses targeted modification strategies for high-current operation. Emphasis is placed on approaches such as electronic structure modulation, stabilization of active sites, optimization of mass transport, and mitigation of catalyst degradation. Finally, future perspectives are proposed to guide the rational design of durable nickel-based electrocatalysts and promote their integration into industrial-scale alkaline electrolyzers.