Three-Dimensional Unified Electrode Design Using a NiFeOOH Catalyst for Superior Performance and Durable Anion-Exchange Membrane Water Electrolyzers

Interfacial and Vacancy Engineering on 3D-Interlocked Anode Catalyst Layer for Achieving Ultralow Voltage in Anion Exchange Membrane Water Electrolyzer

Developing a high-efficiency and stable anode catalyst layer (CL) is crucial for promoting the practical applications of anion exchange membrane (AEM) water electrolyzers. Herein, a hierarchical nanosheet array composed of oxygen vacancy-enriched CoCrOx nanosheets and dispersed FeNi layered double hydroxide (LDH) is proposed to regulate the electronic structure and increase the electrical conductivity for improving the intrinsic activity of the oxygen evolution reaction (OER). The CoCrOx/NiFe LDH electrodes require an overpotential of 205 mV to achieve a current density of 100 mA cm-2, and they exhibit long-term stability at 1000 mA cm-2 over 7000 h. Notably, a breakthrough strategy is introduced in membrane electrode assembly (MEA) fabrication by transferring CoCrOx/NiFe LDH to the surface of an AEM, forming a 3D-interlocked anode CL, significantly reducing the overall cell resistance and enhancing the liquid/gas mass transfer. In AEM water electrolysis, it exhibits an ultralow cell voltage of 1.55 Vcell to achieve a current density of 1.0 A cm-2 in 1 M KOH, outperforming the state-of-the-art Pt/C//IrO2. This work provides a valuable approach to designing high-efficiency electrocatalysts at the single-cell level for advanced alkaline water electrolysis technologies.

Optimizing the Synergistic Effect of Co and Fe for Efficient and Durable Oxygen Evolution under Alkaline Conditions

Developing robust oxygen evolution reaction (OER) electrocatalysts is crucial for advancing anion exchange membrane water electrolysis (AEMWE). In this study, we present a catalyst optimizing the synergistic effect of Co and Fe by creating a CoFe-based layer on a Fe-based electrode (Fe@CoFe). The Fe@CoFe exhibits an overpotential of 168 mV at 10 mA cm-2 under half-cell conditions and a current density of 10 A cm-2 at 2 V in the AEMWE system with 1 M KOH. Moreover, it showcases a degradation rate of 76 μV h-1 for 2000 h at 500 mA cm-2 in the single-cell system. This study demonstrates the feasibility of achieving efficient and durable water electrolysis using a transition metal-based catalyst exclusively fabricated via electrodeposition.

Potassium fluoride-induced FeOOH formation in NiFe oxalate for improved oxygen evolution performance

Our study introduces a facile synthetic route for the in situ formation of nickel (Ni)-iron (Fe) oxyhydroxide from NiFe oxalate. By adding potassium fluoride (KF) to the synthetic solution, we achieved a predominant surface distribution of Fe (>80 at%) while limiting its bulk incorporation compared to solutions without KF. Operando Raman spectroscopy analysis confirms that the enriched Fe predominantly exists as FeOOH. Our optimized catalyst demonstrates significant efficiency, achieving a current density of 10 mA cm-2 at a notably low overpotential of 226 mV.

Constructing regulable supports via non-stoichiometric engineering to stabilize ruthenium nanoparticles for enhanced pH-universal water splitting

Establishing appropriate metal-support interactions is imperative for acquiring efficient and corrosion-resistant catalysts for water splitting. Herein, the interaction mechanism between Ru nanoparticles and a series of titanium oxides, including TiO, Ti4O7 and TiO2, designed via facile non-stoichiometric engineering is systematically studied. Ti4O7, with the unique band structure, high conductivity and chemical stability, endows with ingenious metal-support interaction through interfacial Ti-O-Ru units, which stabilizes Ru species during OER and triggers hydrogen spillover to accelerate HER kinetics. As expected, Ru/Ti4O7 displays ultralow overpotentials of 8 mV and 150 mV for HER and OER with a long operation of 500 h at 10 mA cm-2 in acidic media, which is expanded in pH-universal environments. Benefitting from the excellent bifunctional performance, the proton exchange membrane and anion exchange membrane electrolyzer assembled with Ru/Ti4O7 achieves superior performance and robust operation. The work paves the way for efficient energy conversion devices.

Advanced membrane-based electrode engineering toward efficient and durable water electrolysis and cost-effective seawater electrolysis in membrane electrolyzers

Researchers have been seeking for the most technically-economical water electrolysis technology for entering the next-stage of industrial amplification for large-scale green hydrogen production. Various membrane-based electrolyzers have been developed to improve electric-efficiency, reduce the use of precious metals, enhance stability, and possibly realize direct seawater electrolysis. While electrode engineering is the key to approaching these goals by bridging the gap between catalysts design and electrolyzers development, nevertheless, as an emerging field, has not yet been systematically analyzed. Herein, this review is organized to comprehensively discuss the recent progresses of electrode engineering that have been made toward advanced membrane-based electrolyzers. For the commercialized or near-commercialized membrane electrolyzer technologies, the electrode material design principles are interpreted and the interface engineering that have been put forward to improve catalytic sites utilization and reduce precious metal loading is summarized. Given the pressing issues of electrolyzer cost reduction and efficiency improvement, the electrode structure engineering toward applying precious metal free electrocatalysts is highlighted and sufficient accessible sites within the thick catalyst layers with rational electrode architectures and effective ions/mass transport interfaces are enabled. In addition, this review also discusses the innovative ways as proposed to break the barriers of current membrane electrolyzers, including the adjustments of electrode reaction environment, and the feasible cell-voltage-breakdown strategies for durable direct seawater electrolysis. Hopefully, this review may provide insightful information of membrane-based electrode engineering and inspire the future development of advanced membrane electrolyzer technologies for cost-effective green hydrogen production.

Facile formation of Zn-incorporated NiFe layered double hydroxide as highly-efficient oxygen evolution catalyst

Electrochemical water splitting is the primary method to produce green hydrogen, which is considered an efficient alternative to fossil fuels for achieving carbon neutrality. For meeting the increasing market demand for green hydrogen, high-efficiency, low-cost, and large-scale electrocatalysts are crucial. In this study, we report a simple spontaneous corrosion and cyclic voltammetry (CV) activation method to fabricate Zn-incorporated NiFe layered double hydroxide (LDH) on commercial NiFe foam, which shows excellent oxygen evolution reaction (OER) performance. The electrocatalyst achieves an overpotential of 565 mV and outstanding stability of up to 112 h at 400 mA cm^-2. The active layer for OER is shown to be β-NiFeOOH according to the results of in-situ Raman. Our findings suggest that the NiFe foam treated by simple spontaneous corrosion has promising industrial applications as a highly efficient OER catalyst.

Cooperative Boron and Vanadium Doping of Nickel Phosphides for Hydrogen Evolution in Alkaline and Anion Exchange Membrane Water/Seawater Electrolyzers

Developing low-cost and high-performance transition metal-based electrocatalysts is crucial for realizing sustainable hydrogen evolution reaction (HER) in alkaline media. Here, a cooperative boron and vanadium co-doped nickel phosphide electrode (B, V-Ni₂ P) is developed to regulate the intrinsic electronic configuration of Ni₂ P and promote HER processes. Experimental and theoretical results reveal that V dopants in B, V-Ni₂ P greatly facilitate the dissociation of water, and the synergistic effect of B and V dopants promotes the subsequent desorption of the adsorbed hydrogen intermediates. Benefiting from the cooperativity of both dopants, the B, V-Ni₂ P electrocatalyst requires a low overpotential of 148 mV to attain a current density of -100 mA cm^-2  with excellent durability. The B, V-Ni₂ P is applied as the cathode in both alkaline water electrolyzers (AWEs) and anion exchange membrane water electrolyzers (AEMWEs). Remarkably, the AEMWE delivers a stable performance to achieve 500 and 1000 mA cm^-2  current densities at a cell voltage of 1.78 and 1.92 V, respectively. Furthermore, the developed AWEs and AEMWEs also demonstrate excellent performance for overall seawater electrolysis.

Heterostructure engineering of iridium species on nickel/molybdenum nitride for highly-efficient anion exchange membrane water electrolyzer

Developing highly active electrocatalysts is a pivotal issue for anion-exchange membrane water electrolyzers (AEMWE). However, realizing the continuous hydrogen generation at a large current density remains challenging. Herein, a novel kind of hybrid electrode is successfully developed by introducing trace iridium (Ir) species onto a hierarchical Ni/Mo₅N₆ heterostructure on Ni foam (Ir-Ni/Mo₅N₆/NF). The synergistic advantages of high conductivity, abundant active sites, and strong electronic interaction endow superior reaction kinetics, presenting a highly-active bifunctional electrocatalyst. Remarkably, the Ir-Ni/Mo₅N₆/NF exhibit extremely low overpotentials of 52 mV and 250 mV at 100 mA cm^-2 for hydrogen evolution reaction (HER) and oxygen evolution reaction (OER). By exploiting the Ir-Ni/Mo₅N₆ as both anode/cathode, the constructed AEMWE device delivers superior performance. The current density reaches 2.1 A cm^-2 at a voltage of 2.0 V and 250 mA cm^-2 at 1.8 V in alkaline/neutral media. This work put forward a facile and effective strategy to synthesize advanced bifunctional electrocatalysts for water electrolysis.

Anion-Exchange Membrane Water Electrolyzers

This Review provides an overview of the emerging concepts of catalysts, membranes, and membrane electrode assemblies (MEAs) for water electrolyzers with anion-exchange membranes (AEMs), also known as zero-gap alkaline water electrolyzers. Much of the recent progress is due to improvements in materials chemistry, MEA designs, and optimized operation conditions. Research on anion-exchange polymers (AEPs) has focused on the cationic head/backbone/side-chain structures and key properties such as ionic conductivity and alkaline stability. Several approaches, such as cross-linking, microphase, and organic/inorganic composites, have been proposed to improve the anion-exchange performance and the chemical and mechanical stability of AEMs. Numerous AEMs now exceed values of 0.1 S/cm (at 60-80 °C), although the stability specifically at temperatures exceeding 60 °C needs further enhancement. The oxygen evolution reaction (OER) is still a limiting factor. An analysis of thin-layer OER data suggests that NiFe-type catalysts have the highest activity. There is debate on the active-site mechanism of the NiFe catalysts, and their long-term stability needs to be understood. Addition of Co to NiFe increases the conductivity of these catalysts. The same analysis for the hydrogen evolution reaction (HER) shows carbon-supported Pt to be dominating, although PtNi alloys and clusters of Ni(OH)2 on Pt show competitive activities. Recent advances in forming and embedding well-dispersed Ru nanoparticles on functionalized high-surface-area carbon supports show promising HER activities. However, the stability of these catalysts under actual AEMWE operating conditions needs to be proven. The field is advancing rapidly but could benefit through the adaptation of new in situ techniques, standardized evaluation protocols for AEMWE conditions, and innovative catalyst-structure designs. Nevertheless, single AEM water electrolyzer cells have been operated for several thousand hours at temperatures and current densities as high as 60 °C and 1 A/cm2, respectively.

Electrochemical preparation of nano/micron structure transition metal-based catalysts for the oxygen evolution reaction

Electrochemical water splitting is a promising technology for hydrogen production and sustainable energy conversion, but the existing electrolytic cells lack a sufficient number of robust and highly active anodic electrodes for the oxygen evolution reaction (OER). Electrochemical synthesis technology provides a feasible route for the preparation of independent OER electrodes with high utilization of active sites, fast mass transfer, and a simple preparation process. A comprehensive review of the electrochemical synthesis of nano/microstructure transition metal-based OER materials is provided. First, some fundamentals of electrochemical synthesis are introduced, including electrochemical synthesis strategies, electrochemical synthesis substrates, the electrolyte used in electrochemical synthesis, and the combination of electrochemical synthesis and other synthesis methods. Second, the morphology and properties of electrochemical synthetic materials are summarized and introduced from the viewpoint of structural design. Then, the latest progress regarding the development of transition metal-based OER electrocatalysts is reviewed, including the classification of metals/alloys, oxides, hydroxides, sulfides, phosphides, selenides, and other transition metal compounds. In addition, the oxygen evolution mechanism and rate-determining steps of transition metal-based catalysts are also discussed. Finally, the advantages, challenges, and opportunities regarding the application of electrochemical techniques in the synthesis of transition metal-based OER electrocatalysts are summarized. This review can provide inspiration for researchers and promote the development of water splitting technology.

Construction of Integrated Electrodes with Transport Highways for Pure-Water-Fed Anion Exchange Membrane Water Electrolysis

The design of high-performance and durable electrodes for the oxygen evolution reaction (OER) is crucial for pure-water-fed anion exchange membrane water electrolysis (AEMWE). In this study, an integrated electrode with vertically aligned ionomer-incorporated nickel-iron layered double hydroxide nanosheet arrays, used on one side of the liquid/gas diffusion layer, is fabricated for the OER. Transport highways in the fabricated integrated electrode, significantly improve the transport of liquid/gas, hydroxide ions, and electron in the anode, resulting in a high current density of 1900 mA cm^-2 at 1.90 V in pure-water-fed AEMWE. Specifically, three-electrode and single-cell measurement results indicate that an anion-exchange ionomer can increase the local OH^- concentration on the integrated electrodes surface and facilitate the OER for pure-water-fed AEMWE. This study highlights a new approach to fabricating and understanding electrode architecture with enhanced performance and durability for pure-water-fed AEMWE.

Anion-exchange membrane water electrolyzers and fuel cells

The key components, working management, and operating techniques of anion-exchange membrane water electrolyzers and fuel cells are reviewed for the first time.