Chemical Epitaxy of Iridium Oxide on Tin Oxide Enhances Stability of Supported OER Catalyst

Significantly reducing the iridium content in oxygen evolution reaction (OER) catalysts while maintaining high electrocatalytic activity and stability is a key priority in the development of large-scale proton exchange membrane (PEM) electrolyzers. In practical catalysts, this is usually achieved by depositing thin layers of iridium oxide on a dimensionally stable metal oxide support material that reduces the volumetric packing density of iridium in the electrode assembly. By comparing two support materials with different structure types, it is shown that the chemical nature of the metal oxide support can have a strong influence on the crystallization of the iridium oxide phase and the direction of crystal growth. Epitaxial growth of crystalline IrO2 is achieved on the isostructural support material SnO2, both of which have a rutile structure with very similar lattice constants. Crystallization of amorphous IrOx on an SnO2 substrate results in interconnected, ultrasmall IrO2 crystallites that grow along the surface and are firmly anchored to the substrate. Thereby, the IrO2 phase enables excellent conductivity and remarkable stability of the catalyst at higher overpotentials and current densities at a very low Ir content of only 14 at%. The chemical epitaxy described here opens new horizons for the optimization of conductivity, activity and stability of electrocatalysts and the development of other epitaxial materials systems.

Active and highly durable supported catalysts for proton exchange membrane electrolysers

The design and development of supported catalysts for the oxygen evolution reaction (OER) is a promising pathway to reducing iridium loading in proton exchange membrane water electrolysers. However, supported catalysts often suffer from poor activity and durability, particularly when deployed in membrane electrode assemblies. In this work, we deploy iridium coated hollow titanium dioxide particles as OER catalysts to achieve higher Ir mass activities than the leading commercial catalysts. Critically, we demonstrate state-of-the-art durabilities for supported iridium catalysts when compared against the previously reported values for analogous device architectures, operating conditions and accelerated stress test profiles. Through extensive materials characterisations alongside rotating disk electrode measurements, we investigate the role of conductivity, morphology, oxidation state and crystallinity on the OER electrochemical performance. Our work highlights a new supported catalyst design that unlocks high-performance OER activity and durability in commercially relevant testing configurations.

Supported IrO2 Nanocatalyst with Multilayered Structure for Proton Exchange Membrane Water Electrolysis

The design of a low-iridium-loading anode catalyst layer with high activity and durability is a key challenge for a proton exchange membrane water electrolyzer (PEMWE). Here, the synthesis of a novel supported IrO2 nanocatalyst with a tri-layered structure, dubbed IrO2@TaOx@TaB that is composed of ultrasmall IrO2 nanoparticles anchored on amorphous TaOx overlayer of TaB nanorods is reported. The composite electrocatalyst shows great activity and stability toward the oxygen evolution reaction (OER) in acid, thanks to its dual-interface structural feature. The electronic interaction in IrO2/TaOx interface can regulate the coverage of surface hydroxyl groups, the Ir3+/ Ir4+ ratio, and the redox peak potential of IrO2 for enhancing OER activity, while the dense TaOx overlayer can prevent further oxidation of TaB substrate and stabilize the IrO2 catalytic layers for improving structural stability during OER. The IrO2@TaOx@TaB can be used to fabricate an anode catalyst layer of PEMWE with an iridium-loading as low as 0.26 mg cm-2. The low-iridium-loading PEMWE delivers high current densities at low cell voltages (e.g., 3.9 A cm-2@2.0 V), and gives excellent activity retention for more than 1500 h at 2.0 A cm-2 current density.

Photodeposition-Based Synthesis of TiO2@IrOx Core-Shell Catalyst for Proton Exchange Membrane Water Electrolysis with Low Iridium Loading

The widespread application of green hydrogen production technologies requires cost reduction of crucial elements. To achieve this, a viable pathway to reduce the iridium loading in proton exchange membrane water electrolysis (PEMWE) is explored. Herein, a scalable synthesis method based on a photodeposition process for a TiO2@IrOx core-shell catalyst with a reduced iridium content as low as 40 wt.% is presented. Using this synthesis method, titania support particles homogeneously coated with a thin iridium oxide shell of only 2.1 ± 0.4 nm are obtained. The catalyst exhibits not only high ex situ activity, but also decent stability compared to commercially available catalysts. Furthermore, the unique core-shell structure provides a threefold increased electrical powder conductivity compared to structures without the shell. In addition, the low iridium content facilitates the fabrication of sufficiently thick catalyst layers at decreased iridium loadings mitigating the impact of crack formation in the catalyst layer during PEMWE operation. It is demonstrated that the novel TiO2@IrOx core-shell catalyst clearly outperforms the commercial reference in single-cell tests with an iridium loading below 0.3 mgIr cm-2 exhibiting a superior iridium-specific power density of 17.9 kW gIr -1 compared to 10.4 kW gIr -1 for the commercial reference.

A Co-Doping Materials Design Strategy for Selective Ozone Electrocatalysts

Catalysts for electrochemical ozone production (EOP) face inherent selectivity challenges stemming from thermodynamic constraints. This work establishes a design strategy for minimizing these limitations and inducing EOP activity in tin oxide, which is an intrinsically EOP-inactive material. We propose that selective ozone production using tin oxide catalysts can be broadly achieved by co-doping with two elements: first, n-type dopants to enhance electrical conductivity, and second, transition metal dopants that leach and homogeneously generate essential hydroperoxyl radical intermediates. Synthesizing tantalum, antimony, and tungsten n-type dopants with nickel, cobalt, and iron as transition metal dopants confirms that properly co-doping tin oxide yields EOP-active catalysts. This study offers a robust framework for advancing EOP catalyst design and serves as a case study for the application of fundamental co-catalysis and solid-state physics principles to induce catalytic activity in inert materials.

Influence of Temperature on the Performance of Carbon- and ATO-supported Oxygen Evolution Reaction Catalysts in a Gas Diffusion Electrode Setup

State-of-the-art industrial electrocatalysts for the oxygen evolution reaction (OER) under acidic conditions are Ir-based. Considering the scarce supply of Ir, it is imperative to use the precious metal as efficiently as possible. In this work, we immobilized ultrasmall Ir and Ir_0.4Ru_0.6 nanoparticles on two different supports to maximize their dispersion. One high-surface-area carbon support serves as a reference but has limited technological relevance due to its lack of stability. The other support, antimony-doped tin oxide (ATO), has been proposed in the literature as a possible better support for OER catalysts. Temperature-dependent measurements performed in a recently developed gas diffusion electrode (GDE) setup reveal that surprisingly the catalysts immobilized on commercial ATO performed worse than their carbon-immobilized counterparts. The measurements suggest that the ATO support deteriorates particularly fast at elevated temperatures.

Iridium Stabilizes Ceramic Titanium Oxynitride Support for Oxygen Evolution Reaction

Decreasing iridium loading in the electrocatalyst presents a crucial challenge in the implementation of proton exchange membrane (PEM) electrolyzers. In this respect, fine dispersion of Ir on electrically conductive ceramic supports is a promising strategy. However, the supporting material needs to meet the demanding requirements such as structural stability and electrical conductivity under harsh oxygen evolution reaction (OER) conditions. Herein, nanotubular titanium oxynitride (TiON) is studied as a support for iridium nanoparticles. Atomically resolved structural and compositional transformations of TiON during OER were followed using a task-specific advanced characterization platform. This combined the electrochemical treatment under floating electrode configuration and identical location transmission electron microscopy (IL-TEM) analysis of an in-house-prepared Ir-TiON TEM grid. Exhaustive characterization, supported by density functional theory (DFT) calculations, demonstrates and confirms that both the Ir nanoparticles and single atoms induce a stabilizing effect on the ceramic support via marked suppression of the oxidation tendency of TiON under OER conditions.

Understanding the Stability of Manganese Chromium Antimonate Electrocatalysts through Multimodal In Situ and Operando Measurements

Improving electrocatalyst stability is critical for the development of electrocatalytic devices. Herein, we utilize an on-line electrochemical flow cell coupled with an inductively coupled plasma-mass spectrometer (ICP-MS) to characterize the impact of composition and reactant gas on the multielement dissolution of Mn(-Cr)-Sb-O electrocatalysts. Compared to Mn₂O₃ and Cr₂O₃ oxides, the antimonate framework stabilizes Mn at OER potentials and Cr at both ORR and OER potentials. Furthermore, dissolution of Mn and Cr from Mn(-Cr) -Sb-O is driven by the ORR reaction rate, with minimal dissolution under N₂. We observe preferential dissolution of Cr totaling 13% over 10 min at 0.3, 0.6, and 0.9 V vs RHE, with only 1.5% loss of Mn, indicating an enrichment of Mn at the surface of the particles. Despite this asymmetric dissolution, operando X-ray absorption spectroscopy (XAS) showed no measurable changes in the Mn K-edge at comparable potentials. This could suggest that modification to the Mn oxidation state and/or phase in the surface layer is too small or that the layer is too thin to be measured with the bulk XAS measurement. Lastly, on-line ICP-MS was used to assess the effects of applied potential, scan rate, and current on Mn-Cr-Sb-O during cyclic voltammetry and accelerated stress tests. With this deeper understanding of the interplay between oxygen reduction and dissolution, testing procedures were identified to maximize both activity and stability. This work highlights the use of multimodal in situ characterization techniques in tandem to build a more complete model of stability and develop protocols for optimizing catalyst performance.

Carbon nanotube-titanium dioxide nanocomposite support for improved activity and stability of an iridium catalyst toward the oxygen evolution reaction

In order to improve the electrocatalytic activity and stability of an iridium (Ir) nanoparticle catalyst toward the oxygen evolution reaction (OER) in acidic electrolyte, carbon nanotube and titanium dioxide nanocomposites (CNT@TiO2) are presented as a high-performance support. TiO2 was synthesized on CNTs by using a novel layer-by-layer solution coating method that mimics atomic layer deposition (ALD) but is cost-effective and scalable. In the nanocomposites, CNTs serve as the electron pathways and the surface TiO2 layers protect CNTs from corrosion under the harsh OER conditions. Thus, CNT@TiO2 demonstrates excellent corrosion resistance as well as a high electrical conductivity (1.6 ± 0.2 S cm-1) comparable to that of Vulcan carbon (1.4 S cm-1). The interaction between Ir and TiO2 promotes the formation of Ir(iii) species, thereby enhancing the OER activity and stability of the Ir nanoparticle catalyst. Compared to commercial carbon-supported Ir (Ir/C) and Ir black catalysts, CNT@TiO2-supported Ir exhibits superior OER activity and stability.

Supported Iridium-based Oxygen Evolution Reaction Electrocatalysts - Recent Developments

The commercialization of acidic proton exchange membrane water electrolyzers (PEMWE) is heavily hindered by the price and scarcity of oxygen evolution reaction (OER) catalyst, i. e. iridium and its oxides. One of the solutions to enhance the utilization of this precious metal is to use a support to distribute well dispersed Ir nanoparticles. In addition, adequately chosen support can also impact the activity and stability of the catalyst. However, not many materials can sustain the oxidative and acidic conditions of OER in PEMWE. Hereby, we critically and extensively review the different materials proposed as possible supports for OER in acidic media and the effect they have on iridium performances.

Metallic Inverse Opal Frameworks as Catalyst Supports for High-Performance Water Electrooxidation

High intrinsic activity of oxygen evolution reaction (OER) catalysts is often limited by their low electrical conductivity. To address this, we introduce copper inverse opal (IO) frameworks offering a well-developed network of interconnected pores as highly conductive high-surface-area supports for thin catalytic coatings, for example, the extremely active but poorly conducting nickel-iron layered double hydroxides (NiFe LDH). Such composites exhibit significantly higher OER activity in 1 m KOH than NiFe LDH supported on a flat substrate or deposited as inverse opals. The NiFe LDH/Cu IO catalyst enables oxygen evolution rates of 100 mA cm-2 (727±4 A gcatalyst -1 ) at an overpotential of 0.305±0.003 V with a Tafel slope of 0.044±0.002 V dec-1 . This high performance is achieved with 2.2±0.4 μm catalyst layers, suggesting compatibility of the inverse-opal-supported catalysts with membrane electrolyzers, in contrast to similarly performing 103 -fold thicker electrodes based on foams and other substrates.

Nanostructured IrO x supported on N-doped TiO2 as an efficient electrocatalyst towards acidic oxygen evolution reaction

Reducing the Ir consumption without compromising the catalytic performance for the oxygen evolution reaction (OER) is highly paramount to promote the extensive development of the environmentally-friendly solid polymer electrolyte water electrolysis (SPEWE) system. Herein, TiO2 is doped with N through facile NH3 gas treatment and innovatively employed to support IrO x nanoparticles towards acidic OER. N-doping action not only dramatically boosts the electrical conductivity and dispersing/anchoring effects of TiO2, but also effectively improves the electron-transfer procedure. As a result, the IrO x /N-TiO2 electrocatalyst exhibits prominent catalyst utilization, catalytic activity and stability. Specifically, the overpotential required to deliver 10 mA cm-2 is only 270 mV, and the mass activity climbs to 278.7 A gIr -1 @ 1.55 VRHE. Moreover, the single cell voltage is only 1.761 V @ 2.0 A cm-2 when adopting IrO x /N-TiO2 as the anode catalyst, which is 44 mV lower than that of the commercial IrO2 counterpart.

Inter-relationships between Oxygen Evolution and Iridium Dissolution Mechanisms

The widespread utilization of proton exchange membrane (PEM) electrolyzers currently remains uncertain, as they rely on the use of highly scarce iridium as the only viable catalyst for the oxygen evolution reaction (OER), which is known to present the major energy losses of the process. Understanding the mechanistic origin of the different activities and stabilities of Ir-based catalysts is, therefore, crucial for a scale-up of green hydrogen production. It is known that structure influences the dissolution, which is the main degradation mechanism and shares common intermediates with the OER. In this Minireview, the state-of-the-art understanding of dissolution and its relationship with the structure of different iridium catalysts is gathered and correlated to different mechanisms of the OER. A perspective on future directions of investigation is also given.

Sacrificial Cu Layer Mediated the Formation of an Active and Stable Supported Iridium Oxygen Evolution Reaction Electrocatalyst

The production of hydrogen via a proton-exchange membrane water electrolyzer (PEM-WE) is directly dependent on the rational design of electrocatalysts for the anodic oxygen evolution reaction (OER), which is the bottleneck of the process. Here, we present a smart design strategy for enhancing Ir utilization and stabilization. We showcase it on a catalyst, where Ir nanoparticles are efficiently anchored on a conductive support titanium oxynitride (TiON_x) dispersed over carbon-based Ketjen Black and covered by a thin layer of copper (Ir/CuTiON_x/C), which gets removed in the preconditioning step. Electrochemical OER activity, stability, and structural changes were compared to the Ir-based catalyst, where Ir nanoparticles without Cu are deposited on the same support (Ir/TiON_x/C). To study the effect of the sacrificial less-noble metal layer on the catalytic performance of the synthesized material, characterization methods, namely X-ray powder diffraction, X-ray photoemission spectroscopy, and identical location transmission electron microscopy were employed and complemented with scanning flow cell coupled to an inductively coupled plasma mass spectrometer, which allowed studying the online dissolution during the catalytic reaction. Utilization of these advanced methods revealed that the sacrificial Cu layer positively affects both Ir OER mass activity and its durability, which was assessed via S-number, a recently reported stability metric. Improved activity of Cu analogue was ascribed to the higher surface area of smaller Ir nanoparticles, which are better stabilized through a strong metal–support interaction (SMSI) effect.

On the limitations in assessing stability of oxygen evolution catalysts using aqueous model electrochemical cells

Recent research indicates a severe discrepancy between oxygen evolution reaction catalysts dissolution in aqueous model systems and membrane electrode assemblies. This questions the relevance of the widespread aqueous testing for real world application. In this study, we aim to determine the processes responsible for the dissolution discrepancy. Experimental parameters known to diverge in both systems are individually tested for their influence on dissolution of an Ir-based catalyst. Ir dissolution is studied in an aqueous model system, a scanning flow cell coupled to an inductively coupled plasma mass spectrometer. Real dissolution rates of the Ir OER catalyst in membrane electrode assemblies are measured with a specifically developed, dedicated setup. Overestimated acidity in the anode catalyst layer and stabilization over time in real devices are proposed as main contributors to the dissolution discrepancy. The results shown here lead to clear guidelines for anode electrocatalyst testing parameters to resemble realistic electrolyzer operating conditions.

State-of-the-Art Iridium-Based Catalysts for Acidic Water Electrolysis: A Minireview of Wet-Chemistry Synthesis Methods : Preparation routes for active and durable iridium catalysts

With the increasing demand for clean hydrogen production, both as a fuel and an indispensable reagent for chemical industries, acidic water electrolysis has attracted considerable attention in academic and industrial research. Iridium is a well-accepted active and corrosion-resistant component of catalysts for oxygen evolution reaction (OER). However, its scarcity demands breakthroughs in catalyst preparation technologies to ensure its most efficient utilisation. This minireview focusses on the wet-chemistry synthetic methods of the most active and (potentially) durable iridium catalysts for acidic OER, selected from the recent publications in the open literature. The catalysts are classified by their synthesis methods, with authors’ opinion on their practicality. The review may also guide the selection of the state-of-the-art iridium catalysts for benchmarking purposes.

Effect of the Morphology of the High-Surface-Area Support on the Performance of the Oxygen-Evolution Reaction for Iridium Nanoparticles

The development of affordable, low-iridium-loading, scalable, active, and stable catalysts for the oxygen-evolution reaction (OER) is a requirement for the commercialization of proton-exchange membrane water electrolyzers (PEMWEs). However, the synthesis of high-performance OER catalysts with minimal use of the rare and expensive element Ir is very challenging and requires the identification of electrically conductive and stable high-surface-area support materials. We developed a synthesis procedure for the production of large quantities of a nanocomposite powder containing titanium oxynitride (TiON x ) and Ir. The catalysts were synthesized with an anodic oxidation process followed by detachment, milling, thermal treatment, and the deposition of Ir nanoparticles. The anodization time was varied to grow three different types of nanotubular structures exhibiting different lengths and wall thicknesses and thus a variety of properties. A comparison of milled samples with different degrees of nanotubular clustering and morphology retention, but with identical chemical compositions and Ir nanoparticle size distributions and dispersions, revealed that the nanotubular support morphology is the determining factor governing the catalyst's OER activity and stability. Our study is supported by various state-of-the-art materials' characterization techniques, like X-ray photoelectron spectroscopy, scanning and transmission electron microscopies, X-ray powder diffraction and absorption spectroscopy, and electrochemical cyclic voltammetry. Anodic oxidation proved to be a very suitable way to produce high-surface-area powder-type catalysts as the produced material greatly outperformed the IrO2 benchmarks as well as the Ir-supported samples on morphologically different TiON x from previous studies. The highest activity was achieved for the sample prepared with 3 h of anodization, which had the most appropriate morphology for the effective removal of oxygen bubbles.

Organometallic chemical deposition of crystalline iridium oxide nanoparticles on antimony-doped tin oxide support with high-performance for the oxygen evolution reaction

Organometallic chemical deposition (OMCD) of epitaxially anchored rutile IrO₂ nanoparticles on Sb-doped SnO₂ support, with high-performance towards the oxygen evolution reaction (OER).