Recent Progress on Copper‐Based Electrode Materials for Overall Water‐Splitting

Fabrication of binder-less metal electrodes for electrochemical water splitting - A review

The escalating demand for green hydrogen (H2) as a sustainable energy carrier has attracted intensive research into efficient water electrolysis methods. Promising candidates have emerged as binder-less metal electrodes, which enhance electrochemical performance and durability by reducing electron hindrance and avoiding binder degradation. Despite their potential, a comprehensive understanding of various binder-less fabrication techniques remains limited in the existing literature. As the main objective, this review paper aims to bridge this gap by providing an in-depth analysis of state-of-the-art fabrication methods for binder-less metal electrodes utilized in electrochemical water splitting. Recognizing the critical need for sustainable hydrogen production, the advantages of binder-less electrodes over conventional binder-based counterparts are elucidated, with emphasis placed on their role in promoting cost-effectiveness, improved stability, and enhanced catalytic activity. Techniques such as Hydrothermal/Solvothermal, Electrodeposition, Chemical/Vapor Deposition, and Laser-based fabrication are systematically examined, with their respective advantages, drawbacks, and comparison being highlighted. Drawing upon relevant examples from literature, insights on other aspects and recent trends are also provided, such as the performance of binder-less metal electrodes at industrial-scale current densities (0.1-1 A/cm2) or their potential as photoactive catalysts. Additionally, future directions in the field of binder-less electrode fabrication and the exploration of innovative techniques are also discussed, ensuring that the trajectory of research aligns with the evolving demands of sustainable energy production. The "what's next" section highlights areas of further investigation and potential avenues for technological advancement.

Fabrication of Ru-doped CuMnBP micro cluster electrocatalyst with high efficiency and stability for electrochemical water splitting application at the industrial-level current density

Electrochemical water splitting has been considered as a key pathway to generate environmentally friendly green hydrogen energy and it is essential to design highly efficient electrocatalysts at affordable cost to facilitate the redox reactions of hydrogen evolution reaction (HER) and oxygen evolution reaction (OER). In this work, a novel micro-clustered Ru/CuMnBP electrocatalyst is introduced, prepared via hydrothermal deposition and soaking-assisted Ru doping approaches on Ni foam substrate. Ru/CuMnBP micro-clusters exhibit relatively low HER/OER turnover overpotentials of 11 mV and 85 mV at 10 mA/cm2 in 1 M KOH. It also demonstrates a low 2-E turnover cell voltage of 1.53 V at 10 mA/cm2 for the overall water-splitting, which is comparable with the benchmark electrodes of Pt/C||RuO2. At a super high-current density of 2000 mA/cm2, the dual functional Ru/CuMnBP demonstrates an exceptionally low 2-E cell voltage of 3.13 V and also exhibits superior stability for over 10 h in 1 M KOH. Excellent electrochemical performances originate from the large electrochemical active surface area with the micro cluster morphology, high intrinsic activity of CuMnBP micro-clusters optimized through component ratio adjustment and the beneficial Ru doping effect, which enhances active site density, conductivity and stability. The usage of Ru in small quantities via the simple soaking doping approach significantly improves electrochemical reaction rates for both HER and OER, making Ru/CuMnBP micro-clusters promising candidates for advanced electrocatalytic applications.

Electrocatalytic Properties of Quasi-2D Oxides LaSrMn0.5M0.5O4 (M = Co, Ni, Cu, and Zn) for Hydrogen and Oxygen Evolution Reactions

Designing cost-effective and highly efficient electrocatalysts for water splitting is a significant challenge. We have systematically investigated a series of quasi-2D oxides, LaSrMn0.5M0.5O4 (M = Co, Ni, Cu, Zn), to enhance the electrocatalytic properties of the two half-reactions of water-splitting, namely oxygen and hydrogen evolution reactions (OER and HER). The four materials are isostructural, as confirmed by Rietveld refinements with X-ray diffraction. The oxygen contents and metal valence states were determined by iodometric titrations and X-ray photoelectron spectroscopy. Electrical conductivity measurements in a wide range of temperatures revealed semiconducting behavior for all four materials. Electrocatalytic properties were studied for both half-reactions of water-splitting, namely, oxygen-evolution and hydrogen-evolution reactions (OER and HER). For the four materials, the trends in both OER and HER were the same, which also matched the trend in electrical conductivities. Among them, LaSrMn0.5Co0.5O4 showed the best bifunctional electrocatalytic activity for both OER and HER, which may be attributed to its higher electrical conductivity and favorable electron configuration.

Multi-Active Sites Loaded NiCu-MOF@MWCNTs as a Bifunctional Electrocatalyst for Electrochemical Water Splitting Reaction

Water can be sustainably and ecologically converted by electrocatalysts into hydrogen and oxygen, which, in turn, can be converted into energy. However, the advancement of using water as green energy is hampered by limitations in the study of high-performance catalysts. The purpose of this study was to construct an electrocatalyst by anchoring well-dispersed multiwalled carbon nanotubes (MWCNTs) on nickel-copper (NiCu-MOF) nanoblocks through a simple solvothermal method. The synthesis of NiCu-MOF@MWCNTs demonstrated exceptional electrocatalytic performance for the hydrogen evolution reaction (HER) and oxygen evolution reaction (OER) in an alkaline medium. At 10 mA cm-2 in 1.0 M KOH, the OER and HER performance of the catalyst displays a relatively low overpotential, with only 220 and 78 mV, respectively. Furthermore, the catalytic activity remained unchanged for 24 h in 1.0 M KOH. This performance was superior to the majority of electrocatalysts that have been reported. This was achieved by utilizing the strong synergy that exists between MWCNTs and bimetallic (Ni-Cu) nano blocks present in the metal-organic framework. The enhanced electrocatalytic activity of the nanocomposite can be attributed to the synergistic impact caused by its various components.

In Situ Design of a Nanostructured Interface between NiMo and CuO Derived from Metal-Organic Framework for Enhanced Hydrogen Evolution in Alkaline Solutions

Hydrogen shows great promise as a carbon-neutral energy carrier that can significantly mitigate global energy challenges, offering a sustainable solution. Exploring catalysts that are highly efficient, cost-effective, and stable for the hydrogen evolution reaction (HER) holds crucial importance. For this, metal-organic framework (MOF) materials have demonstrated extensive applicability as either a heterogeneous catalyst or catalyst precursor. Herein, a nanostructured interface between NiMo/CuO@C derived from Cu-MOF was designed and developed on nickel foam (NF) as a competent HER electrocatalyst in alkaline media. The catalyst exhibited a low overpotential of 85 mV at 10 mA cm-2 that rivals that of Pt/C (83 mV @ 10 mA cm-2). Moreover, the catalyst's durability was measured through chronopotentiometry at a constant current density of -30, -100, and -200 mA cm-2 for 50 h each in 1.0 M KOH. Such enhanced electrocatalytic performance could be ascribed to the presence of highly conductive C and Cu species, the facilitated electron transfer between the components because of the nanostructured interface, and abundant active sites as a result of multiple oxidation states. The existence of an ionized oxygen vacancy (Ov) signal was confirmed in all heat-treated samples through electron paramagnetic resonance (EPR) analysis. This revelation sheds light on the entrapment of electrons in various environments, primarily associated with the underlying defect structures, particularly vacancies. These trapped electrons play a crucial role in augmenting electron conductivity, thereby contributing to an elevated HER performance.

Novel mixed heterovalent (Mo/Co)Ox-zerovalent Cu system as bi-functional electrocatalyst for overall water splitting

A novel hybrid ternary metallic electrocatalyst of amorphous Mo/Co oxides and crystallized Cu metal was deposited over Ni foam using a one-pot, simple, and scalable solvothermal technique. The chemical structure of the prepared ternary electrocatalyst was systematically characterized and confirmed via XRD, FTIR, EDS, and XPS analysis techniques. FESEM images of (Mo/Co)Ox-Cu@NF display the formation of 3D hierarchical structure with a particle size range of 3-5 µm. The developed (Mo/Co)Ox-Cu@NF ternary electrocatalyst exhibits the maximum activity with 188 mV and 410 mV overpotentials at 50 mA cm-2 for hydrogen evolution reaction (HER) and oxygen evolution reaction (OER), respectively. Electrochemical impedance spectroscopy (EIS) results for the (Mo/Co)Ox-Cu@NF sample demonstrate the minimum charge transfer resistance (Rct) and maximum constant phase element (CPE) values. A two-electrode cell based on the ternary electrocatalyst just needs a voltage of about 1.86 V at 50 mA cm-2 for overall water splitting (OWS). The electrocatalyst shows satisfactory durability during the OWS for 24 h at 10 mA cm-2 with an increase of only 33 mV in the cell potential.

Surface Structure to Tailor the Electrochemical Behavior of Mixed-Valence Copper Sulfides during Water Electrolysis

The semiconducting behavior of mixed-valence copper sulfides arises from the pronounced covalency of Cu-S bonds and the exchange coupling between CuI and CuII centers. Although electrocatalytic study with digenite Cu9S5 and covellite CuS has been performed earlier, detailed redox chemistry and its interpretation through lattice structure analysis have never been realized. Herein, nanostructured Cu9S5 and CuS are prepared and used as electrode materials to study their electrochemistry. Powder X-ray diffraction (PXRD) and microscopic studies have found the exposed surface of Cu9S5 to be d(0015) and d(002) for CuS. Tetrahedral (Td) CuII, distorted octahedral (Oh) CuII, and trigonal planar (Tp) CuI sites form the d(0015) surface of Cu9S5, while the (002) surface of CuS consists of only Td CuII. The distribution of CuI and CuII sites in the lattice, predicted by PXRD, can further be validated through core-level Cu 2p X-ray photoelectron spectroscopy (XPS). The difference in the electrochemical response of Cu9S5 and CuS arises predominantly from the different copper sites present in the exposed surfaces and their redox states. In situ Raman spectra recorded during cyclic voltammetric study indicates that Cu9S5 is more electrochemically labile compared to CuS and transforms rapidly to CuO/Cu2O. Contact-angle and BET analyses imply that a high-surface-energy and macroporous Cu9S5 surface favors the electrolyte diffusion, which leads to a pronounced redox response. Post-chronoamperometric (CA) characterizations identify the potential-dependent structural transformation of Cu9S5 and CuS to CuO/Cu2O/Cu(OH)2 electroactive species. The performance of the in situ formed copper-oxides towards electrocatalytic water-splitting is superior compared to the pristine copper sulfides. In this study, the redox chemistry of the Cu9S5/CuS has been correlated to the atomic arrangements and coordination geometry of the surface exposed sites. The structure-activity correlation provides in-depth knowledge of how to interpret the electrochemistry of metal sulfides and their in situ potential-driven surface/bulk transformation pathway to evolve the active phase.

Elucidating the Role of Atomically Dilute Copper Centers Impregnating a Phosphamide Polymer for the Preferential Hydrogen Evolution Reaction over CO2 Reduction

Organic polymers have attracted considerable interest in designing a multifunctional electrocatalyst. However, the inferior electro-conductivity of such metal-free polymers is often regarded as a shortcoming. Herein, a nitrogen- and phosphorus-rich polymer with phosphamide functionality (PAP) in the repeating unit has been synthesized from diaminopyridine (DAP) and phenylphosphonic dichloride (PPDC) precursors. The presence of phosphamide oxygen and pyridine nitrogen in the repeating unit of PAP leads to the coordination of the CuII ion and the incorporation of 3.29 wt % in the polymer matrix (Cu30@PAP) when copper salt is used to impregnate the polymer. Combined with a spectroscopic, microscopic, and DFT study, the coordination and geometry of copper in the PAP matrix has been established to be a distorted square planar CuII in a N2O2 ligand environment where phosphamide oxygen and pyridine nitrogen of the PAP coordinate to the metal center. The copper incorporation in the PAP modulates its electrocatalytic activity. On the glassy carbon electrode, PAP shows inferior activity toward the hydrogen evolution reaction (HER) in 0.5 M H2SO4 while 3 wt % copper incorporation (Cu30@PAP) significantly improves the HER performance with an overpotential of 114 mV at 10 mA cm-2. The notable electrochemical activity with Cu30@PAP occurs due to the impregnation of Cu(II) in PAP, improved electro-kinetics, and better charge transfer resistance (Rct). When changing the electrolyte from H2SO4 to CO2-saturated bicarbonate solution at nearly neutral pH, PAP shows HER as the dominant pathway along with the partial reduction of CO2 to formate. Moreover, the use of Cu30@PAP as an electrolcatalyst could not alter the predominant HER path, and only 20% Faradaic efficiency for the CO2 reduced products has been achieved. Post-chronoamperometric characterization of the recovered catalyst suggests an unaltered valence state of the copper ion and the intact chemical structure of PAP. DFT studies unraveled that the copper sites of Cu30@PAP promote water adsorption while phosphamide-NH of the PAP can weakly hold the CO2 adduct via a hydrogen bonding interaction. A detailed calculation has pointed out that the tetra-coordinated copper centers present in the PAP frame are the reactive sites and that the formation of the [CuI-H] intermediate is the rate-limiting step for both HER and its competitive side reaction, i.e., CO2 reduction to formate or CO formation. The high proton concentration in the electrolyte of pH < 7 leads to HER as the predominant pathway. This combined experimental and theoretical study has highlighted the crucial role of copper sites in electrocatalysis, emphasizing the plausible reason for electrocatalytic selectivity.

Doping of Cr to Regulate the Valence State of Cu and Co Contributes to Efficient Water Splitting

Water electrolysis in alkaline media is the most promising technology for hydrogen production, but efficient electrocatalysts are required to reduce the overpotential in HER and OER processes. In this work, the multicomponent transition metal catalyst Cr-Cu/CoO_x was loaded on copper foam by electrodeposition and annealing, and the catalyst exhibited excellent electrochemical activity. The HER overpotential is 21 mV and the OER overpotential is 252 mV at a current density of 10 mA cm^-2. The overall water splitting voltage is 1.51 V, even better than the Pt/C//RuO₂ two-electrode system (1.61 V). The excellent performance of this catalyst is mainly derived from the close synergistic interaction among Cu, Co, and Cr. The doping of Cr modulates the valence states of Cu and Co at the active sites and improves the adsorption of various reaction intermediates. Density functional theory (DFT) calculations show that the doping of Cr can optimize the adsorption of the reaction intermediate H*. Meanwhile, the high-valent Cr and Co promote hydrolysis through strong adsorption with OH^-. The present work provides a reasonable strategy for designing low-cost transition metals as efficient catalysts for water electrolysis.

Cobalt-doped copper vanadate: a dual active electrocatalyst propelling efficient H2 evolution and glycerol oxidation in alkaline water

Strategically doped metal oxide nanomaterials signify a rapidly growing genre of functional materials with a wide range of practical applications. Copper vanadate (CuV) represents one such highly active system, which has been rarely explored following its doping with an abundant first-row transition metal. Here, we have developed a series of CuV samples with varying cobalt(ii) doping concentrations deploying a relatively simple solid state synthetic procedure. Among the samples, the 10% Co(ii)-doped CuV (Co_10%-CuV) exhibited excellent reactivity for both the H₂ evolution reaction (HER) and glycerol oxidation reaction (GOR) in an alkaline aqueous medium (pH 14.0) during cathodic and anodic scans, respectively. During this dual-active catalysis, surface-immobilized Co_10%-CuV operates at exceptionally low overpotentials of 176 mV and 160 mV for the HER and GOR, respectively, while achieving 10 mA cm² current density. The detailed spectroscopic analysis revealed the formation of formate as the major product during the GOR with a faradaic efficiency of >90%. Therefore, this Co_10%-CuV can be included on either side of a two-electrode electrolyzer assembly to trigger a complete biomass-driven H₂ production, establishing an ideal carbon-neutral energy harvest process.

Electrochemically Derived Crystalline CuO from Covellite CuS Nanoplates: A Multifunctional Anode Material

In the present era, electrochemical water splitting has been showcased as a reliable solution for alternative and sustainable energy development. The development of a cheap, albeit active, catalyst to split water at a substantial overpotential with long durability is a perdurable challenge. Moreover, understanding the nature of surface-active species under electrochemical conditions remains fundamentally important. A facile hydrothermal approach is herein adapted to prepare covellite (hexagonal) phase CuS nanoplates. In the covellite CuS lattice, copper is present in a mixed-valent state, supported by two different binding energy values (932.10 eV for Cu^I and 933.65 eV for Cu^II) found in X-ray photoelectron spectroscopy analysis, and adopted two different geometries, that is, trigonal planar preferably for Cu^I and tetrahedral preferably for Cu^II. The as-synthesized covellite CuS behaves as an efficient electro(pre)catalyst for alkaline water oxidation while deposited on a glassy carbon and nickel foam (NF) electrodes. Under cyclic voltammetry cycles, covellite CuS electrochemically and irreversibly oxidized to CuO, indicated by a redox feature at 1.2 V (vs the reversible hydrogen electrode) and an ex situ Raman study. Electrochemically activated covellite CuS to the CuO phase (termed as CuS_EA) behaves as a pure copper-based catalyst showing an overpotential (η) of only 349 (±5) mV at a current density of 20 mA cm^-2, and the TOF value obtained at η₃₄₉ (at 349 mV) is 1.1 × 10^-3 s^-1. A low R_ct of 5.90 Ω and a moderate Tafel slope of 82 mV dec^-1 confirm the fair activity of the CuS_EA catalyst compared to the CuS precatalyst, reference CuO, and other reported copper catalysts. Notably, the CuS_EA/NF anode can deliver a constant current of ca. 15 mA cm^-2 over a period of 10 h and even a high current density of 100 mA cm^-2 for 1 h. Post-oxygen evolution reaction (OER)-chronoamperometric characterization of the anode via several spectroscopic and microscopic tools firmly establishes the formation of crystalline CuO as the active material along with some amorphous Cu(OH)₂ via bulk reconstruction of the covellite CuS under electrochemical conditions. Given the promising OER activity, the CuS_EA/NF anode can be fabricated as a water electrolyzer, Pt(-)//(+)CuS_EA/NF, that delivers a j of 10 mA cm^-2 at a cell potential of 1.58 V. The same electrolyzer can further be used for electrochemical transformation of organic feedstocks like ethanol, furfural, and 5-hydroxymethylfurfural to their respective acids. The present study showcases that a highly active CuO/Cu(OH)₂ heterostructure can be constructed in situ on NF from the covellite CuS nanoplate, which is not only a superior pure copper-based electrocatalyst active for OER and overall water splitting but also for the electro-oxidation of industrial feedstocks.

Dual-electrocatalysis behavior of star-like zinc-cobalt-sulfide decorated with cobalt-molybdenum-phosphide in hydrogen and oxygen evolution reactions

Although important advances have been acquired in the field of electrocatalysis, the design and fabrication of highly efficient and stable non-noble earth-abundant metal catalysts for the oxygen evolution reaction (OER) and hydrogen evolution reaction (HER) remain a significant challenge. In this study, we have designed a superior bifunctional catalyst for OER and HER in alkaline media based on the Co-Mo-P/Zn-Co-S multicomponent heterostructure. The as-prepared multicomponent heterostructure was successfully obtained via a simple three-step hydrothermal-sulfidation-electrodeposition process consisting of star-like Co-Zn-S covered with Co-Mo-P. The structure and morphology evaluation of the prepared catalysts were performed via Fourier transform infrared spectroscopy, X-ray diffraction spectroscopy, field emission scanning electron microscopy, X-ray photoelectron spectroscopy, energy-dispersive X-ray spectroscopy, and elemental mapping techniques. The electrochemical tests show that Co-Mo-P/Co-Zn-S exhibits outstanding activity toward both OER and HER with OER overpotentials of 273 mV and 312 mV to drive the benchmark current densities of 10 and 50 mA cm^-2, respectively, with a Tafel slope of 41 mV dec^-1. In addition, the HER overpotentials of 120 mV and 165 mV were required to reach the benchmark current densities of 10 and 50 mA cm^-2, respectively, with a Tafel slope of 61.7 mV dec^-1 that outperforms most other state-of-the-art catalysts. In the case of HER, the prepared catalyst required an overpotential of 202 mV to reach the current density of 200 mA cm^-2 that was much lower than the overpotential of Pt/C (286 mV) to achieve the same current density. Co-Mo-P/Co-Zn-S also exhibits a suitable stability length of 10 h for OER and HER during the chronoamperometric tests. The superior performance of the Co-Mo-P/Co-Zn-S multicomponent heterostructure toward OER and HER may be related to the large specific surface area, accelerated mass and electron transport, and synergistic effect of multiple hybrid materials. These merits suggest that Co-Mo-P/Co-Zn-S can be considered as a promising catalyst for bi-functional OER and HER, and can be offered a great promise for future applications.

Air-Stable Mn doped CuCl/CuO Hybrid Triquetrous Nanoarrays as Bifunctional Electrocatalysts for Overall Water Splitting

The development of highly efficient non-precious metal catalysts for oxygen evolution reaction (OER) and hydrogen evolution reaction (HER) is key for large-scale hydrogen evolution through water splitting technology. Here, we report an air-stable Cu-based nanostructure consisting of Mn doped CuCl and CuO (CuCl/CuO(Mn)-NF) as a dual functional electrocatalyst for water splitting. CuCl is identified as the main active component, together with Mn doping and the synergistic effect between CuCl and CuO are found to make responsibility for the excellent OER and HER catalytic activity and stability. The assembled electrolyzes also exhibit decent water splitting performance. This work not only provides a simple method for preparing Cu-based composite catalyst, but also demonstrates the great potential of Cu-based non-noble metal electrocatalysts for water splitting and other renewable energy conversion technologies.

Recent advances in activating surface reconstruction for the high-efficiency oxygen evolution reaction

A climax in the development of cost-effective and high-efficiency transition metal-based electrocatalysts has been witnessed recently for sustainable energy and related conversion technologies. In this regard, structure-activity relationships based on several descriptors have already been proposed to rationally design electrocatalysts. However, the dynamic reconstruction of the surface structures and compositions of catalysts during electrocatalytic water oxidation, especially during the anodic oxygen evolution reaction (OER), complicate the streamlined prediction of the catalytic activity. With the achievements in operando and in situ techniques, it has been found that electrocatalysts undergo surface reconstruction to form the actual active species in situ accompanied with an increase in their oxidation state during OER in alkaline solution. Accordingly, a thorough understanding of the surface reconstruction process plays a critical role in establishing unambiguous structure-composition-property relationships in pursuit of high-efficiency electrocatalysts. However, several issues still need to be explored before high electrocatalytic activities can be realized, as follows: (1) the identification of initiators and pathways for surface reconstruction, (2) establishing the relationships between structure, composition, and electrocatalytic activity, and (3) the rational manipulation of in situ catalyst surface reconstruction. In this review, the recent progress in the surface reconstruction of transition metal-based OER catalysts including oxides, non-oxides, hydroxides and alloys is summarized, emphasizing the fundamental understanding of reconstruction behavior from the original precatalysts to the actual catalysts based on operando analysis and theoretical calculations. The state-of-the-art strategies to tailor the surface reconstruction such as substituting/doping with metals, introducing anions, incorporating oxygen vacancies, tuning morphologies and exploiting plasmonic/thermal/photothermal effects are then introduced. Notably, comprehensive operando/in situ characterization together with computational calculations are responsible for unveiling the improvement mechanism for OER. By delivering the progress, strategies, insights, techniques, and perspectives, this review will provide a comprehensive understanding of the surface reconstruction in transition metal-based OER catalysts and future guidelines for their rational development.