Bimetallic Cu–Zn Catalysts for Electrochemical CO2 Reduction: Phase-Separated versus Core–Shell Distribution

Development of supported intermetallic compounds: advancing the Frontiers of heterogeneous catalysis

Intermetallic compound (IMC) catalysts have garnered significant attention due to their unique surface and electronic properties, which can lead to enhanced catalytic performance compared to traditional monometallic catalysts. However, developing IMC materials as high-performance catalysts has been hindered by the inherent complexity of synthesizing nanoparticles with well-defined bulk and surface compositions. Achieving precise control over the composition of supported bimetallic IMC catalysts, especially those with high surface area and stability, has proven challenging. This review provides a comprehensive overview of the recent progress in developing supported IMC catalysts. We first examine the various synthetic approaches that have been explored to prepare supported IMC nanoparticles with phase-pure bulk structures and tailored surface compositions. Key factors influencing the formation kinetics and compositional control of these materials are discussed in detail. Then the strategies for manipulating the surface composition of supported IMCs are delved into. Applications of high-performance supported IMCs in important reactions such as selective hydrogenation, reforming, dehydrogenation, and deoxygenation are comprehensively reviewed, showcasing the unique advantages offered by these materials. Finally, the prevailing research challenges associated with supported IMCs are identified, including the need for a better understanding of the composition-property relationships and the development of scalable synthesis methods. The prospects for the practical implementation of these versatile catalysts in industrial processes are also highlighted, underscoring the importance of continued research in this field.

Regulating Cu Oxidation State for Electrocatalytic CO2 Conversion into CO with Near-Unity Selectivity via Oxygen Spillover

Cu-based catalysts are the most intensively studied in the field of electrocatalytic CO2 reduction reaction (CO2RR), demonstrating the capacity to yield diverse C1 and C2+ products albeit with unsatisfactory selectivity. Manipulation of the oxidation state of Cu sites during CO2RR process proves advantageous in modulating the selectivity of productions, but poses a formidable challenge. Here, an oxygen spillover strategy is proposed to enhance the oxidation state of Cu during CO2RR by incorporating the oxygen donor Sb2O4. The Cu-Sb bimetallic oxide catalyst attains a remarkable CO2-to-CO selectivity approaching unity, in stark contrast to the diverse product distribution observed with bare CuO. The exceptional Faradaic efficiency of CO can be maintained across a wide range of potential windows of ≈700 mV in 1 m KOH, and remains independent of the Cu/Sb ratio (ranging from 0.1:1 to 10:1). Correlative calculations and experimental results reveal that oxygen spillover from Sb2O4 to Cu sites maintains the relatively high valence state of Cu during CO2RR, which diminishes the binding strength of *CO, thereby achieving heightened selectivity in CO production. These findings propose the role of oxygen spillover in CO2RR over Cu-based catalysts, and shed light on the rational design of highly selective CO2 reduction catalysts.

Synthesis and Catalytic Performance of Bimetallic Oxide-Derived CuO-ZnO Electrocatalysts for CO2 Reduction

Steering the selectivity of electrocatalysts toward the desired product is crucial in the electrochemical reduction of CO2. A promising approach is the electronic modification of the catalyst's active phase. In this work, we report on the electronic modification effects on CuO-ZnO-derived electrocatalysts synthesized via hydrothermal synthesis. Although the synthesis method yields spatially separated ZnO nanorods and distinct CuO particles, strong restructuring and intimate atomic mixing occur under the reaction conditions. This leads to interactions that have a profound effect on the catalytic performance. Specifically, all of the bimetallic electrodes outperformed the monometallic ones (ZnO and CuO) in terms of activity for CO production. Surprisingly, on the other hand, the presence of ZnO suppresses the formation of ethylene on Cu, while the presence of Cu improves CO production of ZnO. In situ X-ray absorption spectroscopy studies revealed that this catalytic effect is due to enhanced reducibility of ZnO by Cu and stabilization of cationic Cu species by the intimate contact with partially reduced ZnO. This suppresses ethylene formation while favoring the production of H2 and CO on Cu. These results show that using mixed metal oxides with different reducibilities is a promising approach to alter the electronic properties of electrocatalysts (via stabilization of cationic species), thereby tuning the electrocatalytic CO2 reduction reaction performance.

A Co-Doping Materials Design Strategy for Selective Ozone Electrocatalysts

Catalysts for electrochemical ozone production (EOP) face inherent selectivity challenges stemming from thermodynamic constraints. This work establishes a design strategy for minimizing these limitations and inducing EOP activity in tin oxide, which is an intrinsically EOP-inactive material. We propose that selective ozone production using tin oxide catalysts can be broadly achieved by co-doping with two elements: first, n-type dopants to enhance electrical conductivity, and second, transition metal dopants that leach and homogeneously generate essential hydroperoxyl radical intermediates. Synthesizing tantalum, antimony, and tungsten n-type dopants with nickel, cobalt, and iron as transition metal dopants confirms that properly co-doping tin oxide yields EOP-active catalysts. This study offers a robust framework for advancing EOP catalyst design and serves as a case study for the application of fundamental co-catalysis and solid-state physics principles to induce catalytic activity in inert materials.

Recent Progress on Copper-Based Bimetallic Heterojunction Catalysts for CO2 Electrocatalysis: Unlocking the Mystery of Product Selectivity

Copper-based bimetallic heterojunction catalysts facilitate the deep electrochemical reduction of CO2 (eCO2RR) to produce high-value-added organic compounds, which hold significant promise. Understanding the influence of copper interactions with other metals on the adsorption strength of various intermediates is crucial as it directly impacts the reaction selectivity. In this review, an overview of the formation mechanism of various catalytic products in eCO2RR is provided and highlight the uniqueness of copper-based catalysts. By considering the different metals' adsorption tendencies toward various reaction intermediates, metals are classified, including copper, into four categories. The significance and advantages of constructing bimetallic heterojunction catalysts are then discussed and delve into the research findings and current development status of different types of copper-based bimetallic heterojunction catalysts. Finally, insights are offered into the design strategies for future high-performance electrocatalysts, aiming to contribute to the development of eCO2RR to multi-carbon fuels with high selectivity.

Tailoring the *CO and *H Coverage for Selective CO2 Electroreduction to CH4 or C2H4

In the electrochemical CO2 reduction reaction (CO2RR), the coverages of *CO and *H intermediates on a catalyst surface are critical for the selective generation of C1 or C2 products. In this work, we have synthesized several CuxZnyMnz ternary alloy electrocatalysts, including Cu8ZnMn, Cu8Zn6Mn, and Cu8ZnMn2, by varying the doping compositions of Zn and Mn, which are efficient in binding *CO and *H adsorbates in the CO2 electroreduction process, respectively. The increase of *H coverage allows to promotion of the CH4 and H2 formation, while the increase of the *CO coverage facilitates the production of C2H4 and CO. As a result, the Cu8ZnMn catalyst presented a high CO2-to-CH4 partial current density (-418 ± 22 mA cm-2) with a Faradaic efficiency of 55 ± 2.8%, while the Cu8Zn6Mn catalyst exhibited a CO2-to-C2H4 partial current density (-440 ± 41 mA cm-2) with a Faradaic efficiency of 58 ± 4.5%. The study suggests a useful strategy for rational design and fabrication of Cu electrocatalysts with different doping for tailoring the reduction products.

Study of CuSb bimetallic flow-through gas diffusion electrodes for efficient electrochemical CO2 reduction to CO

Electrochemical CO2 reduction (eCO2R) to industrially important feedstock has received great attention, but it faces different challenges. Among them, the poor CO2 mass transport due to low intrinsic CO2 solubility significantly limits the rate of reduction reactions, leading to lower catalytic performance; thereby, commercially relevant current densities can't be achieved. Moreover, the poor activity and selectivity of high-cost monometallic catalysts, including Cu, Zn, Ag, and Au, undermine the efficiency of eCO2R. Flow-through gas diffusion electrodes (FTGDE), a newly developed class of GDEs, can potentially solve the issue of poor CO2 mass transport because they directly feed the CO2 to the catalyst layer. In addition, abundant surface area, porous structure, and improved triple-phase interface make them an excellent candidate for extremely high rate eCO2R. Antimony, a low-cost and abundant metalloid, can be effectively tuned with Cu to produce useful products such as CO, formate, and C2H4 through eCO2R. Herein, a series of porous binary CuSb FTGDEs with different Sb compositions are fabricated for the electrocatalytic reduction of CO2 to CO. The results show that the catalytic performance of CuSb FTGDEs improved with increasing Sb content up to a certain threshold, beyond which it started to decrease. The CuSb FTGDE with 5.4 g of antimony demonstrated higher current density (206.4 mA/cm2) and faradaic efficiency (72.82 %) at relatively lower overpotentials. Compared to gas diffusion configuration, the poor catalytic activity and selectivity achieved by CuSb FTGDE in non-gas diffusion configuration signifies the importance of improved local CO2 concentration and improved triple-phase interface formation in GDE configuration. The several hours stable operation of CuSb FTGDEs during eCO2R demonstrates its potential for efficient electrocatalytic conversion applications.

Determination of local pH in CO2 electroreduction

The electrocatalytic conversion of CO2 and H2O into fuels and valuable chemicals has gained significant interest as a prospective method for the storage of renewable energy and the utilization of captured CO2. In the process of electroreduction of CO2, pH near the surface of the electrocatalysts plays an important role in the catalytic selectivity and activity. However, to elucidate the local pH effect on the fundamental reaction mechanism and modify the catalytic CO2 reduction performance, the localized pH determination method is highly desirable. In this minireview, we present the recent advances in the strategies of the local pH probe for CO2 electrolysis in both H-type cell reactors and GDE-type flow electrolyzers, followed with a better understanding of the local reaction environment in CO2 reduction. Additionally, pertinent advantages and drawbacks of the different localized pH probe techniques are discussed, and perspectives on future research efforts are also provided in this minireview.

ALD-Engineered CuxO Overlayers Transform ZnO Nanorods for Selective Production of CO in Electrochemical CO2 Reduction

The electrochemical CO2 reduction reaction (CO2RR) holds tremendous promise as a strategy for lowering atmospheric CO2 levels and creating new clean energy sources. The conversion of CO2RR to CO, in particular, has garnered significant scientific interest due to its industrial feasibility. Within this context, the CuZn-based electrocatalyst presents an attractive alternative to conventional CO-selective electrocatalysts, which are often costly and scarce. Nevertheless, the wide-range utilization of CuZn electrocatalysts requires a more comprehensive understanding of their performance and characteristics. In this study, we synthesized ZnO nanorods through electrodeposition and subsequently coated them with CuxO overlayers prepared by atomic layer deposition (ALD). CuxO significantly enhanced CO selectivity, and 88% CO selectivity at a relatively low potential of -0.8 V was obtained on an optimized CuxO overlayer thickness (CuxO-250/ZnO). The addition of CuxO on ZnO was found to dramatically increase the electrochemical surface area (ESCA), lower the charge-transfer resistance (Rct), and introduce new active sites in the ε-CuZn4 phase. Furthermore, electrochemical Raman spectroscopy results showed that the CuxO-250/ALD electrode developed a ZnO layer on the surface during the CO2RR, while the bare ZnO electrode showed no evidence of ZnO during the reaction. These results suggest that the addition of CuxO by ALD played a crucial role in stabilizing ZnO on the surface. The initial amount of CuxO was shown to further affect the redeposition of the ZnO layer and hence affect the final composition of the surface. We attribute the improvement in CO selectivity to the introduction of both ε-CuZn4 and ZnO that developed during the CO2RR. Overall, our study provides new insights into the dynamic behavior and surface composition of CuZn electrocatalysts during CO2RR.

Recent insights on the use of modified Zn-based catalysts in eCO2RR

Converting CO2 into valuable chemicals can provide a new path to mitigate the greenhouse effect, achieving the aim of "carbon neutrality" and "carbon peaking". Among numerous electrocatalysts, Zn-based materials are widely distributed and cheap, making them one of the most promising electrocatalyst materials to replace noble metal catalysts. Moreover, the Zn metal itself has a certain selectivity for CO. After appropriate modification, such as oxide derivatization, structural reorganization, reconstruction of the surfaces, heteroatom doping, and so on, the Zn-based electrocatalysts can expose more active sites and adjust the d-band center or electronic structure, and the FE and stability of them can be effectively improved, and they can even convert CO2 to multi-carbon products. This review aims to systematically describe the latest progresses of modified Zn-based electrocatalyst materials (including organic and inorganic materials) in the electrocatalytic carbon dioxide reduction reaction (eCO2RR). The applications of modified Zn-based catalysts in improving product selectivity, increasing current density and reducing the overpotential of the eCO2RR are reviewed. Moreover, this review describes the reasonable selection and good structural design of Zn-based catalysts, presents the characteristics of various modified zinc-based catalysts, and reveals the related catalytic mechanisms for the first time. Finally, the current status and development prospects of modified Zn-based catalysts in eCO2RR are summarized and discussed.

Opening Direct Electrochemical Fischer-Tropsch Synthesis Path by Interfacial Engineering of Cu Electrode with P-Block Elements

The electrochemical synthesis of syngas (CO and H2) has garnered considerable attention in the context of Fischer-Tropsch (FT) synthesis employing thermal catalysts. Nonetheless, the need for a novel, cost-effective technique persists. In this investigation, we introduce a direct electrochemical (dEC) approach for FT synthesis that functions under ambient conditions by utilizing a p-block element (Sn and In) overlaid Cu electrode. Surface *CO and H* species were obtained in an electrolytic medium through the CO2 + H+ + e- → HOOCad → *CO (or direct CO adsorption) and H+ + e- → H* reactions, respectively. We have observed C2-7 long-chain hydrocarbons with a CnH2n+2/CnH2n ratio of 1-3, and this observation can be explained through the process of C-C coupling chain growth of the conventional FT synthesis, based on the linearity of the Anderson-Schulz-Flory equation plots. Thick Sn and In overlayers resulted in the dominant production of formate, while CO and C2H4 production were found to be proportional and inversely correlated to H2, C2H6, and C3-7 hydrocarbon production. The EC CO2/CO reduction used in dEC FT synthesis offers valuable insights into the mechanism of C2+ production and holds promise as an eco-friendly approach to producing long-chain hydrocarbons for energy and environmental purposes.

Cu and Zn promoted Al-fumarate metal organic frameworks for electrocatalytic CO2 reduction

Metal organic frameworks (MOFs) are attractive materials to generate multifunctional catalysts for the electrocatalytic reduction of CO2 to hydrocarbons. Here we report the synthesis of Cu and Zn modified Al-fumarate (Al-fum) MOFs, in which Zn promotes the selective reduction of CO2 to CO and Cu promotes CO reduction to oxygenates and hydrocarbons in an electrocatalytic cascade. Cu and Zn nanoparticles (NPs) were introduced to the Al-fum MOF by a double solvent method to promote in-pore metal deposition, and the resulting reduced Cu-Zn@Al-fum drop-cast on a hydrophobic gas diffusion electrode for electrochemical study. Cu-Zn@Al-fum is active for CO2 electroreduction, with the Cu and Zn loading influencing the product yields. The highest faradaic efficiency (FE) of 62% is achieved at -1.0 V vs. RHE for the conversion of CO2 into CO, HCOOH, CH4, C2H4 and C2H5OH, with a FE of 28% to CH4, C2H4 and C2H5OH at pH 6.8. Al-fum MOF is a chemically robust matrix to disperse Cu and Zn NPs, improving electrocatalyst lifetime during CO2 reduction by minimizing transition metal aggregation during electrode operation.

Ab initio study for late steps of CO2 and CO electroreduction: from CHCO* toward C2 products on Cu and CuZn nanoclusters

Electroreduction of CO2 to C2 products such as ethanol is motivated by its potential application to satisfy global energy demand in a more sustainable and renewable way. Cooper-based catalysts have exhibited highlighted performance in obtaining C2 products, but large overpotentials and poor selectivity are still challenging. Herein, we employed density functional theory calculations and the computational hydrogen electrode model to study the impact of CuZn alloys on the mechanism and selectivity of CO2 and CO electroreduction to C2 products. On both clusters, the preferred pathway to ethanol and ethylene shares a common intermediate: CH2CHO*. On Cu55, ethanol formation would occur at lower electrode potential than the formation of ethylene, which agrees with experimental studies. Since Cu42Zn13 increases the Gibbs free energy change between CH2CHO* and adsorbed acetaldehyde, the alloy exhibited lower selectivity toward ethanol than Cu55 cluster. The role of Zn is mainly related to the stronger adsorption of the intermediates on Cu42Zn13 than in the Cu55 group. Our results suggested that the d states of Zn are involved in the adsorption of intermediates, strengthening the interaction.

CO Electroreduction Mechanism on Single-Atom Zn (101) Surfaces: Pathway to C2 Products

Electrocatalytic reduction of carbon dioxide (CO₂RR) employs electricity to store renewable energy in the form of reduction products. The activity and selectivity of the reaction depend on the inherent properties of electrode materials. Single-atom alloys (SAAs) exhibit high atomic utilization efficiency and unique catalytic activity, making them promising alternatives to precious metal catalysts. In this study, density functional theory (DFT) was employed to predict stability and high catalytic activity of Cu/Zn (101) and Pd/Zn (101) catalysts in the electrochemical environment at the single-atom reaction site. The mechanism of C2 products (glyoxal, acetaldehyde, ethylene, and ethane) produced by electrochemical reduction on the surface was elucidated. The C-C coupling process occurs through the CO dimerization mechanism, and the formation of the *CHOCO intermediate proves beneficial, as it inhibits both HER and CO protonation. Furthermore, the synergistic effect between single atoms and Zn results in a distinct adsorption behavior of intermediates compared to traditional metals, giving SAAs unique selectivity towards the C2 mechanism. At lower voltages, the Zn (101) single-atom alloy demonstrates the most advantageous performance in generating ethane on the surface, while acetaldehyde and ethylene exhibit significant certain potential. These findings establish a theoretical foundation for the design of more efficient and selective carbon dioxide catalysts.

Cutting-Edge Electrocatalysts for CO2RR

A world-wide growing concern relates to the rising levels of CO₂ in the atmosphere that leads to devastating consequences for our environment. In addition to reducing emissions, one alternative strategy is the conversion of CO₂ (via the CO₂ Reduction Reaction, or CO₂RR) into added-value chemicals, such as CO, HCOOH, C₂H₅OH, CH₄, and more. Although this strategy is currently not economically feasible due to the high stability of the CO₂ molecule, significant progress has been made to optimize this electrochemical conversion, especially in terms of finding a performing catalyst. In fact, many noble and non-noble metal-based systems have been investigated but achieving CO₂ conversion with high faradaic efficiency (FE), high selectivity towards specific products (e.g., hydrocarbons), and maintaining long-term stability is still challenging. The situation is also aggravated by a concomitant hydrogen production reaction (HER), together with the cost and/or scarcity of some catalysts. This review aims to present, among the most recent studies, some of the best-performing catalysts for CO₂RR. By discussing the reasons behind their performances, and relating them to their composition and structural features, some key qualities for an "optimal catalyst" can be defined, which, in turn, will help render the conversion of CO₂ a practical, as well as economically feasible process.

Research Progress of Copper-Based Bimetallic Electrocatalytic Reduction of CO2

Fossil fuels are still the main source of energy in today’s society, so emissions of CO2 are inevitable, but when the CO2 level in the atmosphere is too high, many environmental problems will arise, such as the greenhouse effect, among others. Electrocatalytic reduction of CO2 is one of the most important methods that one can use to reduce the amount of CO2 in the atmosphere. This paper reviews bimetallic catalysts prepared on the basis of copper materials, such as Ag, Au, Zn and Ni. The effects of different ratios of metal atoms in the bimetallic catalysts on the selectivity of CO2RR were investigated and the effects of bimetallic catalysts on the CO2RR of different ligands were also analysed. Finally, this paper points out that the real reaction of CO2RR still needs to be studied and analysed, and the effect of the specific reaction environment on selectivity has not been thoroughly studied. This article also describes some of the problems encountered so far.

Electrochemical Reduction of CO2 to C1 and C2 Liquid Products on Copper-Decorated Nitrogen-Doped Carbon Nanosheets

Due to the significant rise in atmospheric carbon dioxide (CO₂) concentration and its detrimental environmental effects, the electrochemical CO₂ conversion to valuable liquid products has received great interest. In this work, the copper-melamine complex was used to synthesize copper-based electrocatalysts comprising copper nanoparticles decorating thin layers of nitrogen-doped carbon nanosheets (Cu/NC). The as-prepared electrocatalysts were characterized by XRD, SEM, EDX, and TEM and investigated in the electrochemical CO₂ reduction reaction (ECO₂RR) to useful liquid products. The electrochemical CO₂ reduction reaction was carried out in two compartments of an electrochemical H-Cell, using 0.5 M potassium bicarbonate (KHCO₃) as an electrolyte; nuclear magnetic resonance (¹H NMR) was used to analyze and quantify the liquid products. The electrode prepared at 700 °C (Cu/NC-700) exhibited the best dispersion for the copper nanoparticles on the carbon nanosheets (compared to Cu/NC-600 & Cu/NC-800), highest current density, highest electrochemical surface area, highest electrical conductivity, and excellent stability and faradic efficiency (FE) towards overall liquid products of 56.9% for formate and acetate at the potential of -0.8V vs. Reversible Hydrogen Electrode (RHE).