Mesoscale Diffusion Enhancement of Carbon-Bowl-Shaped Nanoreactor toward High-Performance Electrochemical H2O2 Production

Efficient Neutral H2O2 Electrosynthesis from Favorable Reaction Microenvironments via Porous Carbon Carrier Engineering

The efficient electrosynthesis of hydrogen peroxide (H2O2) via two-electron oxygen reduction reaction (2e- ORR) in neutral media is undoubtedly a practical route, but the limited comprehension of electrocatalysts has hindered the system advancement. Herein, we present the design of model catalysts comprising mesoporous carbon spheres-supported Pd nanoparticles for H2O2 electrosynthesis at near-zero overpotential with approximately 95 % selectivity in a neutral electrolyte. Impressively, the optimized Pd/MCS-8 electrocatalyst in a flow cell device achieves an exceptional H2O2 yield of 15.77 mol gcatalyst -1 h-1, generating a neutral H2O2 solution with an accumulated concentration of 6.43 wt %, a level sufficiently high for medical disinfection. Finite element simulation and experimental results suggest that mesoporous carbon carriers promote O2 enrichment and localized pH elevation, establishing a favorable microenvironment for 2e- ORR in neutral media. Density functional theory calculations reveal that the robust interaction between Pd nanoparticles and the carbon carriers optimized the adsorption of OOH* at the carbon edge, ensuring high active 2e- process. These findings offer new insights into carbon-loaded electrocatalysts for efficient 2e- ORR in neutral media, emphasizing the role of carrier engineering in constructing favorable microenvironments and synergizing active sites.

Advancing H2O2 electrosynthesis: enhancing electrochemical systems, unveiling emerging applications, and seizing opportunities

Hydrogen peroxide (H2O2) is a highly desired chemical with a wide range of applications. Recent advancements in H2O2 synthesis center on the electrochemical reduction of oxygen, an environmentally friendly approach that facilitates on-site production. To successfully implement practical-scale, highly efficient electrosynthesis of H2O2, it is critical to meticulously explore both the design of catalytic materials and the engineering of other components of the electrochemical system, as they hold equal importance in this process. Development of promising electrocatalysts with outstanding selectivity and activity is a prerequisite for efficient H2O2 electrosynthesis, while well-configured electrolyzers determine the practical implementation of large-scale H2O2 production. In this review, we systematically summarize fundamental mechanisms and recent achievements in H2O2 electrosynthesis, including electrocatalyst design, electrode optimization, electrolyte engineering, reactor exploration, potential applications, and integrated systems, with an emphasis on active site identification and microenvironment regulation. This review also proposes new insights into the existing challenges and opportunities within this rapidly evolving field, together with perspectives on future development of H2O2 electrosynthesis and its industrial-scale applications.

General Design Concept of High-Performance Single-Atom-Site Catalysts for H2O2 Electrosynthesis

Hydrogen peroxide (H2O2) as a green oxidizing agent is widely used in various fields. Electrosynthesis of H2O2 has gradually become a hotspot due to its convenient and environment-friendly features. Single-atom-site catalysts (SASCs) with uniform active sites are the ideal catalysts for the in-depth study of the reaction mechanism and structure-performance relationship. In this review, the outstanding achievements of SASCs in the electrosynthesis of H2O2 through 2e- oxygen reduction reaction (ORR) and 2e- water oxygen reaction (WOR) in recent years, are summarized. First, the elementary steps of the two pathways and the roles of key intermediates (*OOH and *OH) in the reactions are systematically discussed. Next, the influence of the size effect, electronic structure regulation, the support/interfacial effect, the optimization of coordination microenvironments, and the SASCs-derived catalysts applied in 2e- ORR are systematically analyzed. Besides, the developments of SASCs in 2e- WOR are also overviewed. Finally, the research progress of H2O2 electrosynthesis on SASCs is concluded, and an outlook on the rational design of SASCs is presented in conjunction with the design strategies and characterization techniques.

Efficient Electrosynthesis of Hydrogen Peroxide Using Oxygen-Doped Porous Carbon Catalysts at Industrial Current Densities

Metal-free carbon catalysts (MFCCs) are one of the commonly used catalysts for electrocatalytic two-electron oxygen reduction (2e- ORR) synthesis of hydrogen peroxide (H2O2). Oxygen doping is an effective means to improve the performance of MFCCs, but the performance of oxygen-doped carbon catalysts is still not high enough, and the contribution of different oxygen functional groups (OFGs) to the catalytic performance is still inconclusive. In this paper, carbon-based catalysts with different oxygen contents and ratios of OFGs were prepared, and the high 2e- ORR activity of COOH + C-OH was demonstrated by combining the results of experiments and theoretical calculations. The prepared oxygen-doped carbon-based catalyst C-0.1M80 achieved an onset potential of 0.795 V (vs RHE), a selectivity of up to 98.2% (0.6 V vs RHE), and a H2O2 oxidation current of 1.33 mA cm-2 (0.5 V vs RHE) in a rotating ring-disk electrode test (0.1 M KOH solution), which was an outstanding performance in MFCCs. In a solid electrolyte flow cell, C-0.1M80 achieved a Faraday efficiency of 97.5% at 200 mA cm-2 with a corresponding H2O2 production rate of 123.7 mg cm-2 h-1. In addition, a flow cell stability test was performed at an industrial current density (100 mA cm-2) with an astounding 200 h of uninterrupted operation, also achieving an outstanding average Faradaic efficiency (95.8%).

Sodium chloride modulated construction of hollow Co/Co3O4 heterostructure with enhanced mesoscale diffusion towards overall water splitting

Fabricating an efficient electrocatalyst for both oxygen evolution reaction (OER) and hydrogen evolution reaction (HER) isthe most challenging task for overall water splitting. Herein, we utilized the confinement effect of molten sodium chloride (NaCl) to controllably prepare hollow Co/Co3O4 nanoparticles embedded into nitrogen-doped carbon (H-Co/Co3O4-NC). Experimental and theoretical investigations revealed that the interfacial interaction within Co/Co3O4 heterostructure played a pivotal role in modulating the electronic structure and facilitating the electron transfer. Meanwhile, the superiority of hollow nanostructure could promote the mesoscale mass diffusion. Remarkably, the as-prepared H-Co/Co3O4-NC catalyst achieved the low overpotentials of 316 mV and 252 mV towards OER and HER, respectively, which delivered overall water splitting with the potential of 1.76 V at a current density of 10 mA cm-2.

Nanoengineering of Porous 2D Structures with Tunable Fluid Transport Behavior for Exceptional H2O2 Electrosynthesis

Precision nanoengineering of porous two-dimensional structures has emerged as a promising avenue for finely tuning catalytic reactions. However, understanding the pore-structure-dependent catalytic performance remains challenging, given the lack of comprehensive guidelines, appropriate material models, and precise synthesis strategies. Here, we propose the optimization of two-dimensional carbon materials through the utilization of mesopores with 5-10 nm diameter to facilitate fluid acceleration, guided by finite element simulations. As proof of concept, the optimized mesoporous carbon nanosheet sample exhibited exceptional electrocatalytic performance, demonstrating high selectivity (>95%) and a notable diffusion-limiting disk current density of -3.1 mA cm-2 for H2O2 production. Impressively, the electrolysis process in the flow cell achieved a production rate of 14.39 mol gcatalyst-1 h-1 to yield a medical-grade disinfectant-worthy H2O2 solution. Our pore engineering research focuses on modulating oxygen reduction reaction activity and selectivity by affecting local fluid transport behavior, providing insights into the mesoscale catalytic mechanism.

Mesoporous carbon spheres with programmable interiors as efficient nanoreactors for H2O2 electrosynthesis

The nanoreactor holds great promise as it emulates the natural processes of living organisms to facilitate chemical reactions, offering immense potential in catalytic energy conversion owing to its unique structural functionality. Here, we propose the utilization of precisely engineered carbon spheres as building blocks, integrating micromechanics and controllable synthesis to explore their catalytic functionalities in two-electron oxygen reduction reactions. After conducting rigorous experiments and simulations, we present compelling evidence for the enhanced mass transfer and microenvironment modulation effects offered by these mesoporous hollow carbon spheres, particularly when possessing a suitably sized hollow architecture. Impressively, the pivotal achievement lies in the successful screening of a potent, selective, and durable two-electron oxygen reduction reaction catalyst for the direct synthesis of medical-grade hydrogen peroxide disinfectant. Serving as an exemplary demonstration of nanoreactor engineering in catalyst screening, this work highlights the immense potential of various well-designed carbon-based nanoreactors in extensive applications.

Tailoring the Atomic-Local Environment of Carbon Nanotube Tips for Selective H2 O2 Electrosynthesis at High Current Densities

The atomic-local environment of catalytically active sites plays an important role in tuning the activity of carbon-based metal-free electrocatalysts (C-MFECs). However, the rational regulation of the environment is always impeded by synthetic limitations and insufficient understanding of the formation mechanism of the catalytic sites. Herein, the possible cleavage mechanism of carbon nanotubes (CNTs) through the crossing points during ball-milling is proposed, resulting in abundant CNT tips that are more susceptible to be modified by heteroatoms, achieving precise modulation of the atomic environment at the tips. The obtained CNTs with N,S-rich tips (N,S-TCNTs) exhibit a wide potential window of 0.59 V along with H2 O2 selectivity for over 90.0%. Even using air as the O2 source, the flow cell system with N,S-TCNTs catalyst attains high H2 O2 productivity up to 30.37 mol gcat. -1  h-1 @350 mA cm-2 , superior to most reported C-MFECs. From a practical point of view, a solid electrolyzer based on N,S-TCNTs is further employed to realize the in-situ continuous generation of pure H2 O2 solution with high productivity (up to 4.35 mmol cm-2  h-1 @300 mA cm-2 ; over 300 h). The CNTs with functionalized tips hold great promise for practical applications, even beyond H2 O2 generation.

Balancing Mass Transfer and Active Sites to Improve Electrocatalytic Oxygen Reduction by B,N Codoped C Nanoreactors

Mass transfer is critical in catalytic processes, especially when the reactions are facilitated by nanostructured catalysts. Strong efforts have been devoted to improving the efficacy and quantity of active sites, but often, mass transfer has not been well studied. Herein, we demonstrate the importance of mass transfer in the electrocatalytic oxygen reduction reaction (ORR) by tailoring the pore sizes. Using a confined-etching strategy, we fabricate boron- and nitrogen-doped carbon (B,N@C) electrocatalysts featuring abundant active sites but different porous structures. The ORR performance of these catalysts is found to correlate with diffusion of the reactant. The optimized B,N@C with trimodal-porous structures feature enhanced O₂ diffusion and better activity per heteroatomic site toward the ORR process. This work demonstrates the significance of the nanoarchitecture engineering of catalysts and sheds light on how to optimize structures featuring abundant active sites and enhanced mass transfer.

Nanostructured Silicon Matrix for Materials Engineering

Tin-containing layers with different degrees of oxidation are uniformly distributed along the length of silicon nanowires formed by a top-down method by applying metalorganic chemical vapor deposition. The electronic and atomic structure of the obtained layers is investigated by applying nondestructive surface-sensitive X-ray absorption near edge spectroscopy using synchrotron radiation. The results demonstrated, for the first time, a distribution effect of the tin-containing phases in the nanostructured silicon matrix compared to the results obtained for planar structures at the same deposition temperatures. The amount and distribution of tin-containing phases can be effectively varied and controlled by adjusting the geometric parameters (pore diameter and length) of the initial matrix of nanostructured silicon. Due to the occurrence of intense interactions between precursor molecules and decomposition by-products in the nanocapillary, as a consequence of random thermal motion of molecules in the nanocapillary, which leads to additional kinetic energy and formation of reducing agents, resulting in effective reduction of tin-based compounds to a metallic tin state for molecules with the highest penetration depth in the nanostructured silicon matrix. This effect will enable clear control of the phase distributions of functional materials in 3D matrices for a wide range of applications.

Revealing the atomic-scale configuration modulation effect of boron dopant on carbon layers for H2O2 production

This work reports an atomic-scale carbon layer configuration tuning strategy induced by a boron dopant. Through regulating the doping level of boron, it was found that the boron dopant not only favors carbon layer growth by strengthening the metallic state of the Ni core, but also enhances the abundance of pyrrolic N species and graphitization degree of carbon by tailoring the carbon/nitrogen atom configuration, thereby contributing to more active pyrrolic N/carbon sites and accelerated interface reaction dynamics. Consequently, the developed Ni@B,N-C catalyst achieves remarkable electrochemical H₂O₂ production performances with a high selectivity of 95.5% and a yield of 795 mmol g^-1 h^-1. In comparison with previous reports in which the boron dopant mainly acts as an electronic structure regulator, this study reveals the tuning effect of boron dopants on the atomic-scale carbon layer configuration, opening up a new avenue for the development of advanced catalysts.

Mesoscale Mass Transport Enhancement on Well-Defined Porous Carbon Platform for Electrochemical H2O2 Synthesis

Two-electron oxygen reduction toward hydrogen peroxide (H₂O₂) offers a promising alternative for H₂O₂ production, but its commercial utilization is still hindered by the difficulty of transferring lab-observed catalyst performance to the practical reactor. Here we report the investigation of the porosity engineering effect on catalytic performance inconsistency through a material platform consisting of a series of hollow mesoporous carbon sphere (HMCS) samples. The performance comparison of HMCS samples in rotating ring-disk electrode and Zn-air battery together with the simulation of diffusion behavior reveals that, in low current density conditions, large surface area is preferred, but the mass transport governs the performance in high current density regions. On account of the favorable porous structure, HMCS-8 nm delivers the most excellent practical performance (166 mW cm^-2) and performs well in the bifunctional Zn-air battery for the wastewater purification (70% RhB degraded after 2 min and 99% after 32 min).

Electrocatalytic two-electron oxygen reduction over nitrogen doped hollow carbon nanospheres

The two-electron oxygen reduction reaction (2e^- ORR) has become a hopeful alternative for production of hydrogen peroxide (H₂O₂), but its practical feasibility is hindered by the lack of efficient electrocatalysts to achieve high activity and selectivity. Herein, we successfully synthesized outstanding nitrogen doped hollow carbon nanospheres (NHCSs) for electrochemical production of H₂O₂. In 0.1 M KOH, NHCSs exhibit superior and sustained catalytic activity for the 2e^- ORR with an unordinary selectivity of 96.6%. Impressively, such NHCSs manifest an ultrahigh H₂O₂ yield rate of 7.32 mol g_cat.^-1  h^-1 and a high faradaic efficiency of 96.7% at 0.5 V in an H-cell system. Density functional theory calculations were performed to further reveal the catalytic mechanism involved.

Catalytic confinement effects in nanochannels: from biological synthesis to chemical engineering

Catalytic reactions within nanochannels are of significant importance in disclosing the mechanisms of catalytic confinement effects and developing novel reaction systems for scientific and industrial demands. Interestingly, catalytic confinement effects exist in both biological and artificial nanochannels, which enhance the reaction performance of various chemical reactions. In this minireview, we investigate the recent advances on catalytic confinement effects in terms of the reactants, reaction processes, catalysts, and products in nanochannels. A systematic discussion of catalytic confinement effects associated with biological synthesis in bio-nanochannels and catalytic reactions in artificial nanochannels in chemical engineering is presented. Furthermore, we summarize the properties of reactions both in nature and chemical engineering and provide a brief overlook of this research field.

Coupling Co-N-C with MXenes Yields Highly Efficient Catalysts for H2O2 Production in Acidic Media

The electrochemical oxygen reduction reaction (ORR) offers a promising method to replace the anthraquinone process for hydrogen peroxide (H₂O₂) production. However, the efficiency of this process suffers from sluggish kinetics, particularly in an acidic environment. Therefore, employing catalysts with high electroactivity is highly desirable for H₂O₂ synthesis. Here, an effective strategy for preparing Co-N-C/Ti₃C₂T_x with high H₂O₂ selectivity and ORR reactivity is proposed. The acquired Co-N-C/Ti₃C₂T_x shows excellent H₂O₂ electrosynthesis performance in acidic media with H₂O₂ productivity of up to 3200 ppm h^-1, superior to state-of-the-art catalysts. Interestingly, a H₂O₂ concentration of 6.0 wt % was obtained after the stability test, and the Co-N-C/Ti₃C₂T_x catalyst was found to effectively catalyze organic dye degradation. Further analysis reveals that the enhanced H₂O₂ electrosynthesis performance originates from the layered structure and the oxygen functional groups of Ti₃C₂T_x. The layered structure can effectively promote increased exposure of active sites, while the oxygen functional groups will fine-tune the electronic structure of Co atoms, allowing a selective ORR pathway to produce H₂O₂. This work provides a strategy to design and fabricate highly efficient catalysts for H₂O₂ production and degradation of organic pollutants.