Hydrogen Peroxide Generation with 100% Faradaic Efficiency on Metal-Free Carbon Black

Roles of Oxygen-Containing Functional Groups in Carbon for Electrocatalytic Two-Electron Oxygen Reduction Reaction

Recent years have witnessed great research interests in developing high-performance electrocatalysts for the two-electron (2e-) oxygen reduction reaction (ORR) that enables the sustainable and flexible synthesis of H2O2. Carbon-based electrocatalysts exhibit attractive catalytic performance for the 2e- ORR, where oxygen-containing functional groups (OFGs) play a decisive role. However, current understanding is far from adequate, and the contribution of OFGs to the catalytic performance remains controversial. Therefore, a critical overview on OFGs in carbon-based electrocatalysts toward the 2e- ORR is highly desirable. Herein, we go over the methods for constructing OFGs in carbon including chemical oxidation, electrochemical oxidation, and precursor inheritance. Then we review the roles of OFGs in activating carbon toward the 2e- ORR, focusing on the intrinsic activity of different OFGs and the interplay between OFGs and metal species or defects. At last, we discuss the reasons for inconsistencies among different studies, and personal perspectives on the future development in this field are provided. The results provide insights into the origin of high catalytic activity and selectivity of carbon-based electrocatalysts toward the 2e- ORR and would provide theoretical foundations for the future development in this field.

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%).

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.

Carbon Catalysts Empowering Sustainable Chemical Synthesis via Electrochemical CO2 Conversion and Two-Electron Oxygen Reduction Reaction

Carbon materials hold significant promise in electrocatalysis, particularly in electrochemical CO2 reduction reaction (eCO2 RR) and two-electron oxygen reduction reaction (2e- ORR). The pivotal factor in achieving exceptional overall catalytic performance in carbon catalysts is the strategic design of specific active sites and nanostructures. This work presents a comprehensive overview of recent developments in carbon electrocatalysts for eCO2 RR and 2e- ORR. The creation of active sites through single/dual heteroatom doping, functional group decoration, topological defect, and micro-nano structuring, along with their synergistic effects, is thoroughly examined. Elaboration on the catalytic mechanisms and structure-activity relationships of these active sites is provided. In addition to directly serving as electrocatalysts, this review explores the role of carbon matrix as a support in finely adjusting the reactivity of single-atom molecular catalysts. Finally, the work addresses the challenges and prospects associated with designing and fabricating carbon electrocatalysts, providing valuable insights into the future trajectory of this dynamic field.

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.

Electrogeneration of H2O2 through carbon-based ink on Al foam for electro-Fenton treatment of micropollutants in water

In the present work, the catalytic efficiency of inks based on different carbon materials, namely activated carbon (AC), carbon graphite (CG), and carbon black (CB) was investigated for the oxygen reduction reaction (ORR). Additionally, we explored the feasibility of using this ink as a coating for an Aluminum foam (Alfoam) cathode in an electrochemical cell. The goal was to utilize this setup to produce hydrogen peroxide (H2O2) in the electro-Fenton (EF) process, targeting for treating water contaminated with contaminants of emerging concern (CECs). Among the materials investigated, all of them exhibited the ability to facilitate the ORR. However, AC proved to be the most suitable material due to its optimal balance between physical and electrocatalytic properties, thus enabling the formation of H2O2. When the different inks were applied to the surface of aluminum foam, it was observed that only the ink based on carbon black CB achieved a homogeneous distribution with the same ink quantity. As a result, it was observed that the Alfoam/CB electrode exhibited the highest H2O2 generation capacity, producing 45.6 mg L-1, followed by electro-generation of 5.1 mg L-1 using Alfoam/AC and 11 mg L-1 using Alfoam/CG. Furthermore, the application of Alfoam/CB in EF processes allowed for the almost complete degradation of 15 emerging contaminants of concern (CECs) present in secondary effluent. The innovative outcome of this study positions the developed technology as a promising and effective alternative for the treatment of water contaminated with CECs, demonstrating significant potential for industrial-scale application.

Single-Atom Zinc Sites with Synergetic Multiple Coordination Shells for Electrochemical H2 O2 Production

Precise manipulation of the coordination environment of single-atom catalysts (SACs), particularly the simultaneous engineering of multiple coordination shells, is crucial to maximize their catalytic performance but remains challenging. Herein, we present a general two-step strategy to fabricate a series of hollow carbon-based SACs featuring asymmetric Zn-N2 O2 moieties simultaneously modulated with S atoms in higher coordination shells of Zn centers (n≥2; designated as Zn-N2 O2 -S). Systematic analyses demonstrate that the synergetic effects between the N2 O2 species in the first coordination shell and the S atoms in higher coordination shells lead to robust discrete Zn sites with the optimal electronic structure for selective O2 reduction to H2 O2 . Remarkably, the Zn-N2 O2 moiety with S atoms in the second coordination shell possesses a nearly ideal Gibbs free energy for the key OOH* intermediate, which favors the formation and desorption of OOH* on Zn sites for H2 O2 generation. Consequently, the Zn-N2 O2 -S SAC exhibits impressive electrochemical H2 O2 production performance with high selectivity of 96 %. Even at a high current density of 80 mA cm-2 in the flow cell, it shows a high H2 O2 production rate of 6.924 mol gcat -1  h-1 with an average Faradaic efficiency of 93.1 %, and excellent durability over 65 h.

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.

Defect-stabilized and oxygen-coordinated iron single-atom sites facilitate hydrogen peroxide electrosynthesis

The selective two-electron electrochemical oxygen reduction reaction (ORR) for hydrogen peroxide (H2O2) production is a promising and green alternative method to the current energy-intensive anthraquinone process used in industry. In this study, we develop a single-atom catalyst (CNT-D-O-Fe) by anchoring defect-stabilized and oxygen-coordinated iron atomic sites (Fe-O4) onto porous carbon nanotubes using a local etching strategy. Compared to O-doped CNTs with vacancy defects (CNT-D-O) and oxygen-coordinated Fe single-atom site modifying CNTs without a porous structure (CNT-O-Fe), CNT-D-O-Fe exhibits the highest H2O2 selectivity of 94.4% with a kinetic current density of 13.4 mA cm-2. Fe-O4 single-atom sites in the catalyst probably contribute to the intrinsic reactivity for the two-electron transfer process while vacancy defects greatly enhance the electrocatalytic stability. Theoretical calculations further support that the coordinated environment and defective moiety in CNT-D-O-Fe could efficiently optimize the adsorption strength of the *OOH intermediate over the Fe single atomic active sites. This contribution sheds light on the potential of defect-stabilized and oxygen-coordinated single-atom metal sites as a promising avenue for the rational design of highly efficient and selective catalysts towards various electrocatalytic reactions.

Solvent Engineering of Oxygen-Enriched Carbon Dots for Efficient Electrochemical Hydrogen Peroxide Production

The development of cost-effective and reliable metal-free carbon-based electrocatalysts has gained significant attention for electrochemical hydrogen peroxide (H2 O2 ) generation through a two-electron oxygen reduction reaction. In this study, a scalable solvent engineering strategy is employed to fabricate oxygen-doped carbon dots (O-CDs) that exhibit excellent performance as electrocatalysts. By adjusting the ratio of ethanol and acetone solvents during the synthesis, the surface electronic structure of the resulting O-CDs can be systematically tuned. The amount of edge active CO group was strongly correlated with the selectivity and activity of the O-CDs. The optimum O-CDs-3 exhibited extraordinary H2 O2 selectivity of up to 96.55% (n = 2.06) at 0.65 V (vs RHE) and achieved a remarkably low Tafel plot of 64.8 mV dec-1 . Furthermore, the realistic H2 O2 productivity yield of flow cell is measured to be as high as 111.18 mg h-1  cm-2 for a duration of 10 h. The findings highlight the potential of universal solvent engineering approach for enabling the development of carbon-based electrocatalytic materials with improved performance. Further studies will be undertaken to explore the practical implications of the findings for advancing the field of carbon-based electrocatalysis.

Coherent Sub-Nanometer Interface between Crystalline and Amorphous Materials Boosts Electrochemical Synthesis of Hydrogen Peroxide

There are enormous yet largely underexplored exotic phenomena and properties emerging from interfaces constructed by diverse types of components that may differ in composition, shape, or crystal structure. It remains poorly understood the unique properties a coherent interface between crystalline and amorphous materials may evoke, and there lacks a general strategy to fabricate such interfaces. It is demonstrated that by topotactic partial oxidation heterostructures composed of coherently registered crystalline and amorphous materials can be constructed. As a proof-of-concept study, heterostructures consisting of crystalline P3 N5 and amorphous P3 N5 Ox can be synthesized by creating amorphous P3 N5 Ox from crystalline P3 N5 without interrupting the covalent bonding across the coherent interface. The heterostructure is dictated by nanometer-sized short-range-ordered P3 N5 domains enclosed by amorphous P3 N5 Ox matrix, which entails simultaneously fast charge transfer across the interface and bicomponent synergistic effect in catalysis. Such a P3 N5 /P3 N5 Ox heterostructure attains an optimal adsorption energy for *OOH intermediates and exhibits superior electrocatalytic performance toward H2 O2 production by adopting a selectivity of 96.68% at 0.4 VRHE and a production rate of 321.5 mmol h-1 gcatalyst -1 at -0.3 VRHE . The current study provides new insights into the synthetic strategy, chemical structure, and catalytic property of a sub-nanometer coherent interface formed between crystalline and amorphous materials.

Intermetallic Compound with CuNi Sites for Enhancing the Selectivity of Electrochemical CO2 Conversion

Although single-metal-site (SMS) catalysts have long been explored for the electrochemical CO2 reduction reaction (EC-CO2RR), the reactivity and selectivity of SMS catalysts remain rather low due to the competing hydrogen evolution reaction (HER). To improve the selectivity, in this work, a novel intermetallic particle of CuNi is decorated on the N-doped carbon substrate, which was first precisely fabricated by scarifying the bimetal-doped metal-organic framework (MOF). Thanks to the neighboring synergistic functions of Cu and Ni sites, CuNi/NC prominently boosts the electroreduction of CO2, far more than the SMS catalysts of Cu/NC and Ni/NC. Further, CuNi/NC presents superior selectivity toward CO with faradaic efficiency over a wide range of potentials (surpassing 90% at 0.6-1.0 V vs RHE, up to 98% at 0.6 V vs RHE) and excellent durability. The experimental results and theoretical calculations reveal that the Ni species can be highly activated due to the neighboring Cu species, which considerably facilitates the formation of an intermediate of COOH* and consequently enhances the selectivity of the reduction of CO2 to CO. This work paves a general way to precisely fabricate catalysts with multiple metal species and also demonstrates the significant synergetic efficiency between the neighboring sites to improve the catalytic performance.

Strategies for Sustainable Production of Hydrogen Peroxide via Oxygen Reduction Reaction: From Catalyst Design to Device Setup

An environmentally benign, sustainable, and cost-effective supply of H2O2 as a rapidly expanding consumption raw material is highly desired for chemical industries, medical treatment, and household disinfection. The electrocatalytic production route via electrochemical oxygen reduction reaction (ORR) offers a sustainable avenue for the on-site production of H2O2 from O2 and H2O. The most crucial and innovative part of such technology lies in the availability of suitable electrocatalysts that promote two-electron (2e-) ORR. In recent years, tremendous progress has been achieved in designing efficient, robust, and cost-effective catalyst materials, including noble metals and their alloys, metal-free carbon-based materials, single-atom catalysts, and molecular catalysts. Meanwhile, innovative cell designs have significantly advanced electrochemical applications at the industrial level. This review summarizes fundamental basics and recent advances in H2O2 production via 2e--ORR, including catalyst design, mechanistic explorations, theoretical computations, experimental evaluations, and electrochemical cell designs. Perspectives on addressing remaining challenges are also presented with an emphasis on the large-scale synthesis of H2O2 via the electrochemical route.

Recent Advances of Electrocatalyst and Cell Design for Hydrogen Peroxide Production

Electrochemical synthesis of H2O2 via a selective two-electron oxygen reduction reaction has emerged as an attractive alternative to the current energy-consuming anthraquinone process. Herein, the progress on electrocatalysts for H2O2 generation, including noble metal, transition metal-based, and carbon-based materials, is summarized. At first, the design strategies employed to obtain electrocatalysts with high electroactivity and high selectivity are highlighted. Then, the critical roles of the geometry of the electrodes and the type of reactor in striking a balance to boost the H2O2 selectivity and reaction rate are systematically discussed. After that, a potential strategy to combine the complementary properties of the catalysts and the reactor for optimal selectivity and overall yield is illustrated. Finally, the remaining challenges and promising opportunities for high-efficient H2O2 electrochemical production are highlighted for future studies.

NBOH Site-Activated Graphene Quantum Dots for Boosting Electrochemical Hydrogen Peroxide Production

Carbon materials are considered promising 2/4 e^- oxygen reduction reaction (ORR) electrocatalysts for synthesizing H₂ O₂ /H₂ O via regulating heteroatom dopants and functionalization. Here, various doped and functionalized graphene quantum dots (GQDs) are designed to reveal the crucial active sites of carbon materials for ORR to produce H₂ O₂ . Density functional theory (DFT) calculations predict that the edge structure involving edge N, B dopant pairs and further OH functionalization to the B (NBOH) is an active center for 2e^- ORR. To verify the above predication, GQDs with an enriched density of NBOH (NBO-GQDs) are designed and synthesized by the hydrothermal reaction of NH₂ edge-functionalized GQDs with H₃ BO₃ forming six-member heterocycle containing the NBOH structure. When dispersed on conductive carbon substrates, the NBO-GQDs show H₂ O₂ selectivity of over 90% at 0.7 -0.8 V versus reversible hydrogen electrode in the alkaline solution in a rotating ring-disk electrode setup. The selectivity retains 90% of the initial value after 12 h stability test. In a flow cell setup, the H₂ O₂ production rate is up to 709 mmol g_catalyst ^-1  h^-1 , superior to most reported carbon- and metal-based electrocatalysts. This work provides molecular insight into the design and formulation of highly efficient carbon-based catalysts for sustainable H₂ O₂ production.

Promotion of the Efficient Electrocatalytic Production of H2O2 by N,O- Co-Doped Porous Carbon

H₂O₂ generation via an electrochemical two-electron oxygen reduction (2e^- ORR) is a potential candidate to replace the industrial anthraquinone process. In this study, porous carbon catalysts co-doped by nitrogen and oxygen are successfully synthesized by the pyrolysis and oxidation of a ZIF-67 precursor. The catalyst exhibits a selectivity of ~83.1% for 2e^- ORR, with the electron-transferring number approaching 2.33, and generation rate of 2909.79 mmol g^-1 h^-1 at 0.36 V (vs. RHE) in KOH solution (0.1 M). The results prove that graphitic N and -COOH functional groups act as the catalytic centers for this reaction, and the two functional groups work together to greatly enhance the performance of 2e^- ORR. In addition, the introduction of the -COOH functional group increases the hydrophilicity and the zeta potential of the carbon materials, which also promotes the 2e^- ORR. The study provides a new understanding of the production of H₂O₂ by electrocatalytic oxygen reduction with MOF-derived carbon catalysts.

Toward More Efficient Carbon-Based Electrocatalysts for Hydrogen Peroxide Synthesis: Roles of Cobalt and Carbon Defects in Two-Electron ORR Catalysis

Electrochemical production of H₂O₂ is a cost-effective and environmentally friendly alternative to the anthraquinone-based processes. Metal-doped carbon-based catalysts are commonly used for 2-electron oxygen reduction reaction (2e^-ORR) due to their high selectivity. However, the exact roles of metals and carbon defects on ORR catalysts for H₂O₂ production remain unclear. Herein, by varying the Co loading in the pyrolysis precursor, a Co-N/O-C catalyst with Faradaic efficiency greater than 90% in alkaline electrolyte was obtained. Detailed studies revealed that the active sites in the Co-N/O-C catalysts for 2e^-ORR were carbon atoms in C-O-C groups at defect sites. The direct contribution of cobalt single atom sites and metallic Co for the 2e^-ORR performance was negligible. However, Co plays an important role in the pyrolytic synthesis of a catalyst by catalyzing carbon graphitization, tuning the formation of defects and oxygen functional groups, and controlling O and N concentrations, thereby indirectly enhancing 2e^-ORR performance.

Selective H2O2 Electrosynthesis over Defective Carbon from Electrochemical Etching of Molybdenum Carbide

The controllable synthesis of specific defective carbon catalysts is crucial for two-electron oxygen reduction reaction (2e^- ORR) to generate H₂O₂ due to the great potential applications. Herein, the defective carbon catalysts (Mo-CDC-ns) were prepared by an electrochemical activation (ECA) method with Mo₂C/C as a parent. Electrochemical cyclic voltammetry curves, X-ray photoelectron spectroscopy, inductively coupled plasma-mass spectrometry, scanning electron microscopy, and high-resolution transmission electron microscopy confirm the evolution process of a defective carbon structure from the Mo₂C phase in which Mo species are first oxidized to Mo⁶⁺ species and then the latter are dissolved into the solution and defective carbon is simultaneously formed. Raman and electron paramagnetic resonance spectra reveal that the defect types in Mo-CDC-ns are the edge defect and vacancy defect sites. Compared with the parent Mo₂C/C, Mo-CDC-ns exhibit gradually increased kinetic current density and selectivity for H₂O₂ generation with an extension of activation cycles from 10 (Mo-CDC-10) to 30 (Mo-CDC-30). Over Mo-CDC-30, a kinetic current density of 19.4 mA cm^-2 and a selectivity close to 90% in 0.1 M KOH solution were achieved, as well as good stability for H₂O₂ production in an extended test up to 12 h in an H-cell. Graphene planes and Stone Wales 5757-carbon were constructed as basic models for density functional theory calculations. It revealed that the obtained defective structure after the removal of Mo atoms contains the double vacancy at the edge of graphene (Edge-DVC) and the topological defect on the plane of 5757-carbon (5757C-D), which show more moderate reaction free energy for forming *OOH and smaller energy barrier of 2e^- ORR.

Discriminating active sites for the electrochemical synthesis of H2O2 by molecular functionalisation of carbon nanotubes

The electrochemical production of H₂O₂via the two-electron oxygen reduction reaction (2e^- ORR) has recently attracted attention as a promising alternative to the current anthraquinone process. Identification of active sites in O-doped carbon materials, which exhibit high activities and selectivities for the 2e^- ORR, is important for understanding the selective electrocatalytic process and achieving the rational design of active electrocatalysts. However, this is impeded by the heterogeneous distribution of various active sites on these catalysts. In this study, we exploited the molecular functionalisation approach to implant anthraquinone, benzoic acid, and phenol groups on carbon nanotubes and systematically compared the electrocatalytic activities and selectivities of these functional groups. Among these oxygen functional groups, the anthraquinone group showed the highest surface-area-normalised and active-site-normalised activities.

Anion-tuned nickel chalcogenides electrocatalysts for efficient 2e- ORR towards H2O2 production in acidic media

Electrocatalytic 2e- oxygen reduction reaction (2e- ORR) is a promising approach to producing H2O2 at ambient temperature and pressure especially in acidic media, which, however, is hindered by the high cost of precious metal-based electrocatalysts. Hence, the development of efficient earth-abundant electrocatalysts and reaction mechanism exploration for H2O2 production by 2e- ORR in acidic solution are critically important but remain challenging at present. In this work, NiSe2 has been developed as a novel and high-performance 2e- ORR electrocatalyst in acidic media, moreover, using nickel chalcogenides as the models, the influence of different anion species (Se22-, S22-, and O2-) on 2e- ORR electrocatalytic performance of the catalysts has been investigated. The synthesized NiSe2 exhibits outstanding 2e- ORR performance of high selectivity (90%) and long-term durability (12 h). The maximum H2O2 concentration of NiSe2 reaches 988 ppm, which is the highest among all the reported transition metal chalcogenides. This work demonstrates a novel point of view in anion tuning for designing high-efficiency transition-metal-based electrocatalysts for 2e- ORR.

Electronic Supplementary Material

Supplementary material (additional experimental procedures, characterizations, and computational details) is available in the online version of this article at 10.1007/s12274-022-5160-2.

Robust Superhydrophobic Surfaces via the Sand-In Method

Superhydrophobic surfaces have gained sustained attention because of their extensive applications in the fields of self-cleaning, anti-icing, and drag reduction systems. Water droplets must have large apparent contact angle (CA) (>150°) and small CA hysteresis (<10°) on these surfaces. However, previous research usually involves complex fabrication strategies to modify the surface wettability. It is also challenging to maintain the temporal and mechanical stability of the delicate surface textures. Here, we develop a one-step solvent-free sand-in method to fabricate robust superhydrophobic surfaces directly atop various substrates with an apparent CA up to ∼163.8° and hysteresis less than 5°. The water repellency can withstand 100 Scotch tape peeling tests and remain stable after being stored under ambient humid conditions in Houston, Texas, for 18 months or being heated at 130 °C in air for 24 h. The superhydrophobic surfaces have excellent anti-icing ability, including a ∼2.6× longer water freezing time and ∼40% smaller ice adhesion strength with the temperature as low as -35 °C. Since the surface layers are fabricated by sanding the substrates with the powder additives, the surface damage can be repaired by a direct re-sanding treatment with the same powder additives. Further sand-in condition screenings broaden surface wettability from hydrophilic to superhydrophobic. The sand-in method induces the surface modification and the formation of the tribofilm. Surface and materials characterizations reveal that both microstructures and nanoscale asperities of the tribofilms contribute to the robust superhydrophobic features of sanded surfaces.

Holey and Wrinkled Flash Graphene from Mixed Plastic Waste

High surface area varieties of graphene have captured significant attention, allowing for improved performance in a variety of applications. However, there are challenges facing the use of graphene in these applications since it is expensive and difficult to synthesize in bulk. Here, we leverage the capabilities of flash Joule heating to synthesize holey and wrinkled flash graphene (HWFG) in seconds from mixed plastic waste feedstocks, using in situ salt decomposition to produce and stabilize pore formation during the reaction. Surface areas as high as 874 m² g^-1 are obtained, with characteristics of micro-, meso-, and macroporosities. Raman spectroscopy confirms the wrinkled and turbostratic nature of the HWFG. We demonstrate HWFG applications in its use as a metal-free hydrogen evolution reaction electrocatalyst, with excellent stability, competitive overpotential, and Tafel slope; in a Li-metal battery anode allowing for stable and high discharge rates; and in a material with high gas adsorption. This represents an upcycle of mixed plastic waste, thereby affording a valuable route to address this pressing environmental pollutant concern.

Heteroatom-Doped Flash Graphene

Heteroatom doping can effectively tailor the local structures and electronic states of intrinsic two-dimensional materials, and endow them with modified optical, electrical, and mechanical properties. Recent studies have shown the feasibility of preparing doped graphene from graphene oxide and its derivatives via some post-treatments, including solid-state and solvothermal methods, but they require reactive and harsh reagents. However, direct synthesis of various heteroatom-doped graphene in larger quantities and high purity through bottom-up methods remains challenging. Here, we report catalyst-free and solvent-free direct synthesis of graphene doped with various heteroatoms in bulk via flash Joule heating (FJH). Seven types of heteroatom-doped flash graphene (FG) are synthesized through millisecond flashing, including single-element-doped FG (boron, nitrogen, oxygen, phosphorus, sulfur), two-element-co-doped FG (boron and nitrogen), as well as three-element-co-doped FG (boron, nitrogen, and sulfur). A variety of low-cost dopants, such as elements, oxides, and organic compounds are used. The graphene quality of heteroatom-doped FG is high, and similar to intrinsic FG, the material exhibits turbostraticity, increased interlayer spacing, and superior dispersibility. Electrochemical oxygen reduction reaction of different heteroatom-doped FG is tested, and sulfur-doped FG shows the best performance. Lithium metal battery tests demonstrate that nitrogen-doped FG exhibits a smaller nucleation overpotential compared to Cu or undoped FG. The electrical energy cost for the synthesis of heteroatom-doped FG synthesis is only 1.2 to 10.7 kJ g^-1, which could render the FJH method suitable for low-cost mass production of heteroatom-doped graphene.

Impact of Pore Structure on Two-Electron Oxygen Reduction Reaction in Nitrogen-Doped Carbon Materials: Rotating Ring-Disk Electrode vs. Flow Cell

The impact of pore structure on the two-electron oxygen reduction reaction (ORR) in nitrogen-doped carbon materials is currently under debate, and previous studies are mainly limited to the rotating ring-disk electrode (RRDE) rather than the practical flow cell (FC) system. In this study, assisted by a group of reliable pore models, the impact of two pore structure parameters, that is, Brunauer-Emmett-Teller surface area (S_BET ) and micropore surface fraction (f_micro ), on ORR activity and selectivity are investigated in both RRDE and FC. The ORR mass activity correlates positively to the S_BET in the RRDE and FC because a higher S_BET can host more active sites. The H₂ O₂ selectivity is independent of f_micro in the RRDE but correlates negatively to f_micro in the FC. The inconsistency results from different states of the electrode in the RRDE and the FC. These insights will guide the design of carbon materials for H₂ O₂ synthesis.

Electrosynthesis of >20 g/L H2O2 from Air

Hydrogen peroxide (HP) production via electrochemical oxygen reduction reaction (ORR-HP) is a critical reaction for energy storage and environmental remediation. The onsite production of high-concentration H₂O₂ using gas diffusion electrodes (GDEs) fed by air is especially attractive. However, many studies indicate that the air-GDE combination could not produce concentrated H₂O₂, as the [H₂O₂] leveled off or even decreased with the increasing reaction time. This study proves that the limiting factors are not the oxygen concentration in the air but the anodic and cathodic depletion of the as-formed H₂O₂. We proved that the anodic depletion could be excluded by adopting a divided electrolytic cell. Furthermore, we demonstrated that applying poly(tetrafluoroethylene) (PTFE) as an overcoating rather than a catalyst binder could effectively mitigate the cathodic decomposition pathways. Beyond that, we further developed a composite electrospun PTFE (E-PTFE)/carbon black (CB)/GDE electrode featuring the electrospun PTFE (E-PTFE) nanofibrous overcoating. The E-PTFE coating provides abundant triphase active sites and excludes the cathodic depletion reaction, enabling the production of >20 g/L H₂O₂ at a current efficiency of 86.6%. Finally, we demonstrated the efficacy of the ORR-HP device in lake water remediation. Cyanobacteria and microcystin-LR were readily removed along with the onsite production of H₂O₂.

N-doped carbon nanotubes supported CoSe2 nanoparticles: A highly efficient and stable catalyst for H2O2 electrosynthesis in acidic media

Electrocatalytic oxygen reduction reaction (ORR) provides an attractive alternative to anthraquinone process for H₂O₂ synthesis. Rational design of earth-abundant electrocatalysts for H₂O₂ synthesis via a two-electron ORR process in acids is attractive but still very challenging. In this work, we report that nitrogen-doped carbon nanotubes as a multi-functional support for CoSe₂ nanoparticles not only keep CoSe₂ nanoparticles well dispersed but alter the crystal structure, which in turn improves the overall catalytic behaviors and thereby renders high O₂-to-H₂O₂ conversion efficiency. In 0.1 M HClO₄, such CoSe₂@NCNTs hybrid delivers a high H₂O₂ selectivity of 93.2% and a large H₂O₂ yield rate of 172 ppm·h^-1 with excellent durability up to 24 h. Moreover, CoSe₂@NCNTs performs effectively for organic dye degradation via electro-Fenton process.

ELECTRONIC SUPPLEMENTARY MATERIAL

Supplementary material (SEM images, EDX mapping images, XPS spectrum, XRD patterns, RRDE voltammogram, Tafel plots, cyclic voltammograms, UV-Vis spectra, and Tables S1) is available in the online version of this article at 10.1007/s12274-021-3474-0.

Unveiling the Cationic Promotion Effect of H2O2 Electrosynthesis Activity of O-Doped Carbons

H₂O₂ electrosynthesis is an emerging clean chemical technology, whose efficiency critically depends on the activity and selectivity of electrocatalysts for two-electron oxygen reduction reaction (2e^- ORR). Here, we demonstrate that 2e^- ORR activity of oxygen-doped carbons, which have been one of the most promising catalysts for this reaction, can be substantially influenced by the types and concentrations of cations in electrolytes. Heat-treated carbon comprising active oxygen functional groups exhibits cation-dependent 2e^- ORR activity trends in alkaline media, following the order Cs⁺ > K⁺ > Li⁺. Importantly, an electrolyte with a high cation concentration (0.1 M KOH + 0.5 M KCl) afforded the highest 2e^- ORR mass activity (250 ± 30 A g_cat^-1 at 0.70 V vs reversible hydrogen electrode) ever reported. We have established that the cation promotion effect correlates with cation-dependent electron-transfer kinetics, which regulates the rate-determining first electron transfer to O₂.

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

Gas-involving electrocatalytic reactions are of critical importance in the development of carbon-neutral energy technologies. However, the catalytic performance is always limited by the unsatisfactory diffusion properties of reactants as well as products. In spite of significant advances in catalyst design, the development of mesoscale mass diffusion and process intensification is still challenging due to the lack of material platforms, synthesis methods, and mechanism understanding. In this work, as a proof of concept, we demonstrated achieving these two critical factors in one system by designing a mesoporous carbon bowl (MCB) nanoreactor with both abundant highly active sites and enhanced diffusion properties. The catalysts with controlled opening morphology and mesoporous channels were carefully synthesized via a hydrogen-bonding uneven self-assembling followed by pyrolysis. Taking the two-electron oxygen reduction reaction (ORR) for the H₂O₂ production as a model, which is a strong diffusion-limiting reaction, the optimal MCB samples achieved a high H₂O₂ selectivity (>90%) across a wide potential window of 0.6 V, and a large cathodic current density of -2.7 mA cm^-2 (at 0.1 V vs RHE). The electrochemical evaluation and finite-element simulation study for a series of MCBs revealed that the similar active sites intrinsically determined the H₂O₂ selectivity, while the well-designed mesoporous bowl configuration with different window sizes boosted the ORR activity by significantly accelerating the local mass diffusion. This work sheds new insights into the engineering of intrinsic active sites and local mass diffusion properties for electrocatalysts, which bridges the research of electrocatalysis from fundamental atomic-scale and practical macroscale devices.

Chemical Identification of Catalytically Active Sites on Oxygen-doped Carbon Nanosheet to Decipher the High Activity for Electro-synthesis Hydrogen Peroxide

Electrochemical production of hydrogen peroxide (H₂ O₂ ) through two-electron (2 e^- ) oxygen reduction reaction (ORR) is an on-site and clean route. Oxygen-doped carbon materials with high ORR activity and H₂ O₂ selectivity have been considered as the promising catalysts, however, there is still a lack of direct experimental evidence to identify true active sites at the complex carbon surface. Herein, we propose a chemical titration strategy to decipher the oxygen-doped carbon nanosheet (OCNS₉₀₀ ) catalyst for 2 e^- ORR. The OCNS₉₀₀ exhibits outstanding 2 e^- ORR performances with onset potential of 0.825 V (vs. RHE), mass activity of 14.5 A g^-1 at 0.75 V (vs. RHE) and H₂ O₂ production rate of 770 mmol g^-1  h^-1 in flow cell, surpassing most reported carbon catalysts. Through selective chemical titration of C=O, C-OH, and COOH groups, we found that C=O species contributed to the most electrocatalytic activity and were the most active sites for 2 e^- ORR, which were corroborated by theoretical calculations.