H2O2 direct synthesis under mild conditions on Pd–Au samples: Effect of the morphology and of the composition of the metallic phase

In Situ Performance Monitoring of Electrochemical Oxygen and Hydrogen Peroxide Sensors in an Additively Manufactured Modular Microreactor

Miniaturized and microstructured reactors in process engineering are essential for a more decentralized, flexible, sustainable, and resilient chemical production. Modern, additive manufacturing methods for metals enable complex reactor-geometries, increased functionality, and faster design iterations, a clear advantage over classical subtractive machining and polymer-based approaches. Integrated microsensors allow online, in situ process monitoring to optimize processes like the direct synthesis of hydrogen peroxide. We developed a modular tube-in-tube membrane reactor fabricated from stainless steel via 3D printing by laser powder bed fusion of metals (PBF-LB/M). The reactor concept enables the spatially separated dosage and resaturation of two gaseous reactants across a membrane into a liquid process medium. Uniquely, we integrated platinum-based electrochemical sensors for the online detection of analytes to reveal the dynamics inside the reactor. An advanced chronoamperometric protocol combined the simultaneous concentration measurement of hydrogen peroxide and oxygen with monitoring of the sensor performance and self-calibration in long-term use. We demonstrated the highly linear and sensitive monitoring of hydrogen peroxide and dissolved oxygen entering the liquid phase through the membrane. Our measurements delivered important real-time insights into the dynamics of the concentrations in the reactor, highlighting the power of electrochemical sensors applied in process engineering. We demonstrated the stable continuous measurement over 1 week and estimated the sensor lifetime for months in the acidic process medium. Our approach combines electrochemical sensors for process monitoring with advanced, additively manufactured stainless steel membrane microreactors, supporting the power of sensor-equipped microreactors as contributors to the paradigm change in process engineering and toward a greener chemistry.

Graphene family for hydrogen peroxide production in electrochemical system

The development of carbon-based materials to catalyze two-electron (2e^-) pathway of oxygen reduction reaction (ORR) offers great potential for hydrogen peroxide (H₂O₂) production. As a class of novel two-dimensional (2D) carbon materials, graphene and its derivatives have raised increasing attention as excellent noble-metal-free catalysts in 2e ORR due to their unique structure, physical and chemical properties. This review focuses on the synthesis of main graphene family members and graphene based electrodes, as well as their applications for H₂O₂ generation in electrochemical systems. We describe the functions of the graphene family in electrochemical systems, such as accelerating electron transfer and increasing oxygen transfer for cathodes in electrochemical systems, aiming to reveal the enhancement mechanisms of graphene and its derivatives on H₂O₂ production. Furthermore, the challenges and prospects for graphene family used as catalyst for H₂O₂ production in the future are also proposed.

The Direct Synthesis of Hydrogen Peroxide over AuPd Nanoparticles: An Investigation into Metal Loading

The direct synthesis of H2O2 from molecular H2 and O2 over AuPd catalysts, supported on TiO2 and prepared via an excess chloride co-impregnation procedure is investigated. The role of Au:Pd ratio on the catalytic activity towards H2O2 formation and its subsequent degradation is evaluated under conditions that have previously been found to be optimal for the formation of H2O2. The combination of relatively small nanoparticles, of mixed Pd-oxidation state is shown to correlate with enhanced catalytic performance. Subsequently, a detailed study of catalytic activity towards H2O2 synthesis as a function of AuPd loading was conducted, with a direct correlation between catalytic activity and metal loading observed.

Graphic Abstract

The synergistic effect of the carbon shell pore volume and core Pd size of Pd@hollow@C-X for the synthesis of H2O2

Yolk–shell Pd@hollow@C-X (X = 1.5, 3.2, 4.5 and 6) catalysts with Pd as the core and porous carbon as the shell were prepared via the inverse microemulsion method.

Gold–palladium colloids as catalysts for hydrogen peroxide synthesis, degradation and methane oxidation: effect of the PVP stabiliser

PVP polymer stabilisers effect the reactivity of AuPd nanoparticles towards H₂O₂ synthesis/decomposition and methane oxidation.

Hydrogen peroxide generation from O2 electroreduction for environmental remediation: A state-of-the-art review

The electrochemical production of hydrogen peroxide (H2O2) by 2-electron oxygen reduction reaction (ORR) is an attractive alternative to the present complex anthraquinone process. The objective of this paper is to provide a state-of-the-arts review of the most important aspects of this process. First, recent advances in H2O2 production are reviewed and the advantages of H2O2 electrogeneration via 2-electron ORR are highlighted. Second, the selectivity of the ORR pathway towards H2O2 formation as well as the development process of H2O2 production are presented. The cathode characteristics are the decisive factors of H2O2 production. Thus the focus is shifted to the introduction of commonly used carbon cathodes and their modification methods, including the introduction of other active carbon materials, hetero-atoms doping (i.e., O, N, F, B, and P) and decoration with metal oxides. Cathode stability is evaluated due to its significance for long-term application. Effects of various operational parameters, such as electrode potential/current density, supporting electrolyte, electrolyte pH, temperature, dissolved oxygen, and current mode on H2O2 production are then discussed. Additionally, the environmental application of electrogenerated H2O2 on aqueous and gaseous contaminants removal, including dyes, pesticides, herbicides, phenolic compounds, drugs, VOCs, SO2, NO, and Hg0, are described. Finally, a brief conclusion about the recent progress achieved in H2O2 electrogeneration via 2-electron ORR and an outlook on future research challenges are proposed.

Looking for the “Dream Catalyst” for Hydrogen Peroxide Production from Hydrogen and Oxygen

The reaction between hydrogen and oxygen is in principle the simplest method to form hydrogen peroxide, but it is still a “dream process”, thus needing a “dream catalyst”. The aim of this review is to analyze critically the different heterogeneous catalysts used for the direct synthesis of H2O2 trying to determine the features that the ideal or “dream catalyst” should possess. This analysis will refer specifically to the following points: (i) the choice of the metal; (ii) the metal promoters used to improve the activity and/or the selectivity; (iii) the role of different supports and their acidic properties; (iv) the addition of halide promoters to inhibit undesired side reactions; (v) the addition of other promoters; (vi) the effects of particle morphology; and (vii) the effects of different synthetic methods on catalyst morphology and performance.

How Does the Oxidation State of Palladium Surfaces Affect the Reactivity and Selectivity of Direct Synthesis of Hydrogen Peroxide from Hydrogen and Oxygen Gases? A Density Functional Study

Direct synthesis of H₂O₂ from H₂ and O₂ is an environmentally benign and atom economic process and as such is the ideal pathway in catalysis. However, currently no low-cost pathway of this kind of catalysis exists, although it would be an attractive alternative strategy to the common industrial anthraquinone method for H₂O₂ production. Metal-based catalysts are widely employed in such a direct synthesis process but often need to be oxidized, alloyed, or supplied with additives to make them selective. To understand the metal-oxidation state in heterogeneous catalysis, we studied the selective oxidation of hydrogen by molecular oxygen on Pd(111) and PdO(101) surfaces, leading to either H₂O₂ or H₂O products. Our results demonstrate, for the first time, that the oxidized PdO(101) surface clearly shows better performance and selectivity, as compared to the reduced Pd(111) one. The activation barrier on the oxidized Pd surface is ca. 0.2 eV lower than the one on the reduced Pd surface. On the oxidized surface, the H₂O₂ synthesis route is preferred, while, on the reduced surface, the H₂O route is predominant. The decomposition of H₂O₂ is also greatly inhibited on the oxidized surface. We analyzed the different pathways in detail through thermochemical cycles, which establishes that the oxidized surface shows weaker adsorption ability toward the reagents O₂ and H₂, the key intermediate OOH, and also the product H₂O₂ in comparison with the Pd(111) surface, which we believe affect the selectivity. The work presented here clearly shows that the oxidation state of metal surfaces is one of the most important factors that tunes the catalysis of a chemical reaction and can affect the selectivity and reaction patterns dramatically.

Boosting the Characterization of Heterogeneous Catalysts for H2O2 Direct Synthesis by Infrared Spectroscopy

Infrared (IR) spectroscopy is among the most powerful spectroscopic techniques available for the morphological and physico-chemical characterization of catalytic systems, since it provides information on (i) the surface sites at an atomic level, (ii) the nature and structure of the surface or adsorbed species, as well as (iii) the strength of the chemical bonds and (iv) the reaction mechanism. In this review, an overview of the main contributions that have been determined, starting from IR absorption spectroscopy studies of catalytic systems for H2O2 direct synthesis, is given. Which kind of information can be extracted from IR data? IR spectroscopy detects the vibrational transitions induced in a material by interaction with an electromagnetic field in the IR range. To be IR active, a change in the dipole moment of the species must occur, according to well-defined selection rules. The discussion will be focused on the advancing research in the use of probe molecules to identify (and possibly, quantify) specific catalytic sites. The experiments that will be presented and discussed have been carried out mainly in the mid-IR frequency range, between approximately 700 and 4000 cm−1, in which most of the molecular vibrations absorb light. Some challenging possibilities of utilizing IR spectroscopy for future characterization have also been envisaged.

Gold-Palladium Nanoalloys Supported by Graphene Oxide and Lamellar TiO2 for Direct Synthesis of Hydrogen Peroxide

Hybrid catalysts composed of gold-palladium nanoalloys that are sandwiched between layers of graphene oxide (GO) and lamellar TiO₂ are synthesized via the deposition-reduction method. The resulting AuPd catalysts with different compositions of metal and support are fully characterized by a series of techniques, including X-ray diffraction, scanning transmission electron microscopy, X-ray photoelectron spectroscopy, and inductively coupled plasma mass spectrometry. The catalysts are also optimized against Au, Pd, GO, and TiO₂ contents and employed in the direct synthesis of hydrogen peroxide (DSHP) from H₂ and O₂. The sandwich-like AuPd nanoalloy comprising 1 wt % nanoparticle of an equimolar mixture of Au and Pd with 6 wt % GO and 93 wt % TiO₂ supports shows a promising catalytic performance toward the DSHP reaction with H₂O₂ productivity and selectivity of 5.50 mol H₂O₂ g_metal^-1 h^-1 and 64%, respectively. The catalyst is found to be considerably more active than those reported in the literature. Furthermore, the H₂O₂ selectivity of the catalyst is found to improve considerably to 88% when the TiO₂ support is pretreated by HNO₃. It is found that the perimeter sites of the interface of AuPd alloy and TiO₂ are deemed as catalytically active sites for the DSHP reactions and the acidic property of TiO₂ can retard the other overreactions and the decomposition of yielded H₂O₂. Results of the present study may provide a design strategy for partially covered catalysts that are confined by 2D materials for selective reactions.

Highly Active, Selective, and Stable Direct H2O2 Generation by Monodispersive Pd-Ag Nanoalloy

Hydrogen peroxide (H₂O₂), a green oxidant, has wide applications in various chemical syntheses and is also a promising candidate to replace the traditional toxic oxidants. The direct synthesis of H₂O₂ from H₂ and O₂ is a potential approach, as it is a green and atomically economic reaction. However, the most previous systems are notorious in complicated post-purification procedures, high energy cost, and low selectivity because of the uncontrollable O-O bond cleavage. We have solved this challenge by tuning the chemical state of Pd with high H₂O₂ productivity of 80.4 mol kg_cat^-1 h^-1 and high H₂O₂ selectivity of 82.1% via the design of Pd-Ag nanoalloys with flexibly tuned size and composition. The created Pd-Ag nanoalloy also exhibits excellent stability with limited performance decay over recycles. The X-ray photoelectron spectroscopy analysis confirms the electron transfer from Ag to Pd, which generates more Pd⁰ and enables improved H₂O₂ productivity. The theoretical calculation shows that the incorporation of Ag into Pd is beneficial for the stabilization of O₂^2- and the cleavage of H₂ for the enhanced H₂O₂ generation. In addition, the enhanced H₂O₂ desorption on Pd-Ag nanoalloy is beneficial for releasing H₂O₂, which results in the increased H₂O₂ selectivity.

Porous Nanocrystalline Silicon Supported Bimetallic Pd-Au Catalysts: Preparation, Characterization, and Direct Hydrogen Peroxide Synthesis

Bimetallic Pd-Au catalysts were prepared on the porous nanocrystalline silicon (PSi) for the first time. The catalysts were tested in the reaction of direct hydrogen peroxide synthesis and characterized by standard structural and chemical techniques. It was shown that the Pd-Au/PSi catalyst prepared from conventional H₂[PdCl₄] and H[AuCl₄] precursors contains monometallic Pd and a range of different Pd-Au alloy nanoparticles over the oxidized PSi surface. The PdAu₂/PSi catalyst prepared from the [Pd(NH₃)₄][AuCl₄]₂ double complex salt (DCS) single-source precursor predominantly contains bimetallic Pd-Au alloy nanoparticles. For both catalysts the surface of bimetallic nanoparticles is Pd-enriched and contains palladium in Pd⁰ and Pd²⁺ states. Among the catalysts studied, the PdAu₂/PSi catalyst was the most active and selective in the direct H₂O₂ synthesis with H₂O₂ productivity of 0.5 mol gPd-1 h-1 at selectivity of 50% and H₂O₂ concentration of 0.023 M in 0.03 M H₂SO₄-methanol solution after 5 h on stream at −10°C and atmospheric pressure. This performance is due to high activity in the H₂O₂ synthesis reaction and low activities in the undesirable H₂O₂ decomposition and hydrogenation reactions. Good performance of the PdAu₂/PSi catalyst was associated with the major part of Pd in the catalyst being in the form of the bimetallic Pd-Au nanoparticles. Porous silicon was concluded to be a promising catalytic support for direct hydrogen peroxide synthesis due to its inertness with respect to undesirable side reactions, high thermal stability, and conductivity, possibility of safe operation at high temperatures and pressures and a well-established manufacturing process.

Enhancement of catalytic activity of Pd-PVP colloid for direct H2O2 synthesis from H2 and O2 in water with addition of 0.5 atom% Pt or Ir

Atomically dispersed Pt or Ir atoms enhance H₂O₂ and H₂O formation on Pd nano-particles leaving the H₂O₂ hydrogenation rate unchanged, while Ru, Rh, or Au atoms show little effect.

Some Aspects on the One-Pot Fabrication of Nanoporous Pd-Au Surface Films by Electrochemical Alloying/Dealloying of (Pd-Au)-Zn from a Chlorozincate Ionic Liquid

The high thermal stability of the Lewis acidic ZnCl₂-1-ethyl-3-methylimidazolium chloride ionic liquid enables the in situ fabrication of hierarchical nanostructured Pd-Au bimetallic surfaces via electrochemical alloying/dealloying of (PdAu)Zn on PdAu substrate in the ionic liquid. Nanostructured PdAu samples that consist of patterned cracks and ligaments are fabricated by using potential cycling method and constant-potential electrolysis method, respectively. The effects of working temperature and amounts of the deposited Zn on the morphology of the dealloyed (PdAu)Zn nanostructure are examined. The formation of the hierarchical nanostructure is a compromise between high-surface-diffusive Au and low-surface-diffusive Pd. Whereas Au in the alloy promotes the nanostructure formation, Pd in the PdAu nanostructure protects this material from coarsening. Compared with the plain PdAu, the nanostructured PdAu surface prepared at 150 °C exhibits a significantly higher active surface area and a high capability for the electro-oxidation of glucose.

TiO2 nanoparticles vs. TiO2 nanowires as support in hydrogen peroxide direct synthesis: the influence of N and Au doping

Nitrogen doping is a new strategy to improve catalysts for H₂O₂ direct synthesis.

A review on research progress in the direct synthesis of hydrogen peroxide from hydrogen and oxygen: noble-metal catalytic method, fuel-cell method and plasma method

The direct synthesis of H₂O₂ from H₂ and O₂ using Pd catalyst, fuel cell and plasma methods have been reviewed systematically.

The use of modelling to understand the mechanism of hydrogen peroxide direct synthesis from batch, semibatch and continuous reactor points of view

Modelling is a powerful tool to understand the mechanism of H₂O₂ direct synthesis.

Characterisation of gold catalysts

Au-based catalysts have established a new important field of catalysis, revealing specific properties in terms of both high activity and selectivity for many reactions.

Catalysts for direct H2O2 synthesis taking advantage of the high H2 activating ability of Pt: kinetic characteristics of Pt catalysts and new additives for improving H2O2 selectivity

To develop efficient catalysts for the direct H₂O₂ synthesis from H₂ and O₂ by taking advantage of the high H₂ activating ability of Pt, kinetic studies of the H₂–O₂ reaction were performed using a Pt-PVP (polyvinylpyrrolidone) colloid and Pt supported on carbon (Pt/C) as catalysts, and new additives were explored.

The influence of catalyst amount and Pd loading on the H2O2 synthesis from hydrogen and oxygen

Direct synthesis of H₂O₂: structure sensitivity in H₂O₂ production and structure insensitivity in the H₂O production were proved with a Pd/K2621 catalyst.