Emerging carbon shell-encapsulated metal nanocatalysts for fuel cells and water electrolysis

Platinum nanoparticles wrapped in carbon-dot-films as oxygen reduction reaction catalysts prepared by solution plasma sputtering

Fuel cells have become increasingly important in recent years because of their high energy efficiency and low environmental impact. However, key challenges remain in the widespread adoption of fuel-cell vehicles, including reducing Pt usage in catalysts and improving their durability. In this study, a high-performance Pt@carbon-dot-film core-shell catalyst was successfully synthesized using a nonequilibrium reaction field, i.e., solution plasma (SP) process, by adjusting the electrolyte pH. Four pH solutions (pH = 4.4, 7, 8, and 11) were employed as the discharge liquid environment for the SP process. The catalyst synthesized in the pH = 8 solution exhibited a mass activity of approximately 500 mA mg-1, which was twice as high as that of the commercial Pt/C catalyst (256 mA mg-1) with the same loading amount. The onset and half-wave potentials were 0.99 and 0.89 V, respectively, both of which exceeded those of commercial Pt/C catalysts (0.95 and 0.86 V, respectively). Furthermore, the enhanced catalytic performance corresponded to the Pt/C bonding between Pt and the carbon shell generated during the SP process.

Ruthenium Clusters Modification Carbon Layer-Encapsulated NiCoP Nanoneedles as Advanced Electrocatalyst for Efficient Seawater Splitting Application

Developing efficient and durable electrocatalyst for seawater splitting is crucial in hydrogen production. Herein, a multi-scale design strategy was employed to fabricate ruthenium clusters modification carbon layer-encapsulated nickel-cobalt-phosphorus (Ru/C/NiCoP) nanoneedles electrocatalyst supported on nickel foam (NF). We demonstrated that Ru/C/NiCoP/NF exhibited exceptional oxygen evolution reaction (OER) and hydrogen evolution reaction (HER) performances, with low overpotential, Tafel slope and superior stability. Furthermore, the electrocatalytic mechanism of Ru/C/NiCoP was elucidated through the combination of ex-situ and in-situ characterizations, along with comprehensive electrochemical tests. Strikingly, Ru clusters and the NiCoP with carbon layer engendered robust electronic interaction reaction, accelerated the charge transfer rate, provided more active sites, and enhanced intrinsic catalytic activity, thus substantially promoting the OER kinetics and HER reaction steps as well as stability. In addition, the two-electrode system constructed with Ru/C/NiCoP/NF achieved current density of 10 mA cm-2 in both pure water and seawater at ultra-low potential of 1.46/1.47 V, with Faraday efficiency close to 100 %. Even at higher current density of 100 mA cm-2, the required driving voltage remained low at 1.75/1.77 V, maintaining stable operation for 150 h, outperforming most reported non-noble catalysts. This innovative strategy provides facile and versatile approach for developing advanced electrocatalysts in seawater electrolysis application.

Ultrathin Carbon Shell Protecting Copper Sites to Boost Anodic Hydrogen Production via Low-Potential Formaldehyde Oxidation

The oxidation of aldehydes on a copper-based electrocatalyst within a small potential window can produce hydrogen at the anode, thus offering a bipolar hydrogen production system. However, the inherent activity and stability of Cu-based electrocatalysts for aldehyde oxidation are still not satisfactory in practical application. Herein, by coating an ultrathin carbon shell on the copper sphere, an effective and stable formaldehyde oxidation reaction (FOR) can be realized to produce H2 at a very low potential. FOR needs only a potential of 0.13 V (vs RHE) to reach a current density of 100 mA cm-2. By coupling FOR with hydrogen evolution reaction (HER), hydrogen is generated simultaneously at both the cathode and the anode. The Faraday efficiency of H2 at the bipolar state is close to 100%. In a flow cell, it needs a low cell voltage of 0.1 V to reach a current density of 100 mA cm-2. Moreover, it can be operated steadily for more than 30 h at high current density. The carbon shell acts as an armor to protect the Cu(0) sites, avoid the oxidation of copper, and keep the catalyst activity for a long time in the electrolytic process. Experimental and theoretical calculation results indicate that electron transfer occurs at the interface between the copper core and ultrathin carbon shell. The ultrathin carbon-coated Cu reduces the reaction energy barrier, making the C-H bond more easily fractured and facilitating H coupling to generate H2. This study provides a basic principle for the design of copper-based electrocatalysts with long durability and activity.

Integration Construction of Hybrid Electrocatalysts for Oxygen Reduction

There is notable progress in the development of efficient oxygen reduction electrocatalysts, which are crucial components of fuel cells. However, these superior activities are limited by imbalanced mass transport and cannot be fully reflected in actual fuel cell applications. Herein, the design concepts and development tracks of platinum (Pt)-nanocarbon hybrid catalysts, aiming to enhance the performance of both cathodic electrocatalysts and fuel cells, are presented. This review commences with an introduction to Pt/C catalysts, highlighting the diverse architectures developed to date, with particular emphasis on heteroatom modification and microstructure construction of functionalized nanocarbons based on integrated design concepts. This discussion encompasses the structural evolution, property enhancement, and catalytic mechanisms of Pt/C-based catalysts, including rational preparation recipes, superior activity, strong stability, robust metal-support interactions, adsorption regulation, synergistic pathways, confinement strategies, ionomer optimization, mass transport permission, multidimensional construction, and reactor upgrading. Furthermore, this review explores the low-barrier or barrier-free mass exchange interfaces and channels achieved through the impressive multidimensional construction of Pt-nanocarbon integrated catalysts, with the goal of optimizing fuel cell efficiency. In conclusion, this review outlines the challenges associated with Pt-nanocarbon integrated catalysts and provides perspectives on the future development trends of fuel cells and beyond.

Tailoring Cu-Based Electrocatalysts for Enhanced Electrochemical CO2 Reduction to Alcohols: Structure-Selectivity Relationship

The use of CO2 as a feedstock for the production of carbon-based fuels and value-added chemicals offers a promising route toward carbon neutrality. In this study, two Cu-based electrocatalysts, namely, Cu24/N-C and Cu2/N-C, are successfully prepared by thermal treatment of Cu24 metal-organic polyhedron-loaded zeolitic imidazolate framework-8 (ZIF-8) nanocrystals (Cu24/ZIF-8) and Cu2 dinuclear compound-loaded ZIF-8 nanocrystals (Cu2/ZIF-8), respectively. Extensive structural and compositional analyses were conducted to confirm the formation of Cu nanocluster-loaded N-doped porous carbon supports in both Cu24/N-C and Cu2/N-C and Cu nanoparticles encapsulated by graphitic carbons in Cu2/N-C as well. These two Cu-based electrocatalysts exhibited different behaviors in the electrochemical CO2 reduction reaction (CO2RR). The Cu24/N-C electrocatalyst showed high selectivity for CO production, while Cu2/N-C showed a preference for alcohol generation. The excellent stability of Cu2/N-C over a 30 h continuous electrochemical reduction further highlights its potential for practical applications. The difference in electrocatalytic performance observed in the two catalysts for CO2RR was attributed to distinct catalytic sites associated with Cu nanoclusters and nanoparticles. This research reveals the significance of their structures and compositions for the development of highly selective electrocatalysts for CO2 reduction.

Effect of Heat Treatment on Structure of Carbon Shell-Encapsulated Pt Nanoparticles for Fuel Cells

Polymer electrolyte membrane fuel cells (PEMFCs) have attracted much attention as highly efficient, eco-friendly energy conversion devices. However, carbon-supported Pt (Pt/C) catalysts for PEMFCs still have several problems, such as low long-term stability, to be widely commercialized in fuel cell applications. To address the stability issues of Pt/C such as the dissolution, detachment, and agglomeration of Pt nanoparticles under harsh operating conditions, we design an interesting fabrication process to produce a highly active and durable Pt catalyst by introducing a robust carbon shell on the Pt surface. Furthermore, this approach provides insights into how to regulate the carbon shell layer for fuel cell applications. Through the application of an appropriate amount of H2 gas during heat treatment, the carbon shell pores, which are integral to the structure, can be systematically modulated to facilitate oxygen adsorption for the oxygen reduction reaction. Simultaneously, the carbon shell functions as a protective barrier, preventing catalyst degradation. In this regard, we investigate an in-depth analysis of the effects of critical parameters including H2 content and the flow rate of H2/N2 mixed gas during heat treatment to prepare better catalysts.

Redesign of Anode Catalyst for Sustainable Survival of Fuel Cells

Polymer electrolyte membrane fuel cells (PEMFCs) suffer from severe performance degradation when operating under harsh conditions such as fuel starvation, shut-down/start-up, and open circuit voltage. A fundamental solution to these technical issues requires an integrated approach rather than condition-specific solutions. In this study, an anode catalyst based on Pt nanoparticles encapsulated in a multifunctional carbon layer (MCL), acting as a molecular sieve layer and protective layer is designed. The MCL enabled selective hydrogen oxidation reaction on the surface of the Pt nanoparticles while preventing their dissolution and agglomeration. Thus, the structural deterioration of a membrane electrode assembly can be effectively suppressed under various harsh operating conditions. The results demonstrated that redesigning the anode catalyst structure can serve as a promising strategy to maximize the service life of the current PEMFC system.

Origin and Formation Mechanism of Carbon Shell-Encapsulated Metal Nanoparticles for Powerful Fuel Cell Durability

Proton exchange membrane fuel cells (PEMFCs) face technical issues of performance degradation due to catalyst dissolution and agglomeration in real-world operations. To address these challenges, intensive research has been recently conducted to introduce additional structural units on the catalyst surface. Among various concepts for surface modification, carbon shell encapsulation is known to be a promising strategy since the carbon shell can act as a protective layer for metal nanoparticles. As an interesting approach to form carbon shells on catalyst surfaces, the precursor ligand-induced formation is preferred due to its facile synthesis and tunable control over the carbon shell porosity. However, the origin of the carbon source and the carbon shell formation mechanism have not been studied in depth yet. Herein, this study aims to investigate carbon sources through the use of different precursors and the introduction of new methodologies related to the ligand exchange phenomenon. Subsequently, we provide new insights into the carbon shell formation mechanism using X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD). Finally, the thermal stability and electrochemical durability of carbon shells are thoroughly investigated through in situ transmission electron microscopy (in situ TEM) and accelerated durability tests.

Effect of Carbon Layer Thickness on the Electrocatalytic Oxidation of Glucose in a Ni/BDD Composite Electrode

High-performance non-enzymatic glucose sensor composite electrodes were prepared by loading Ni onto a boron-doped diamond (BDD) film surface through a thermal catalytic etching method. A carbon precipitate with a desired thickness could be formed on the Ni/BDD composite electrode surface by tuning the processing conditions. A systematic study regarding the influence of the precipitated carbon layer thickness on the electrocatalytic oxidation of glucose was conducted. While an oxygen plasma was used to etch the precipitated carbon, Ni/BDD-based composite electrodes with the precipitated carbon layers of different thicknesses could be obtained by controlling the oxygen plasma power. These Ni/BDD electrodes were characterized by SEM microscopies, Raman and XPS spectroscopies, and electrochemical tests. The results showed that the carbon layer thickness exerted a significant impact on the resulting electrocatalytic performance. The electrode etched under 200 W power exhibited the best performance, followed by the untreated electrode and the electrode etched under 400 W power with the worst performance. Specifically, the electrode etched under 200 W was demonstrated to possess the highest sensitivity of 1443.75 μA cm-2 mM-1 and the lowest detection limit of 0.5 μM.

Electrochemical Nitrogen Fixation for Green Ammonia: Recent Progress and Challenges

Ammonia, a key feedstock used in various industries, has been considered a sustainable fuel and energy storage option. However, NH3 production via the conventional Haber-Bosch process is costly, energy-intensive, and significantly contributing to a massive carbon footprint. An electrochemical synthetic pathway for nitrogen fixation has recently gained considerable attention as NH3 can be produced through a green process without generating harmful pollutants. This review discusses the recent progress and challenges associated with the two relevant electrochemical pathways: direct and indirect nitrogen reduction reactions. The detailed mechanisms of these reactions and highlight the recent efforts to improve the catalytic performances are discussed. Finally, various promising research strategies and remaining tasks are presented to highlight future opportunities in the electrochemical nitrogen reduction reaction.

Carbonization of a Molybdenum Substrate Surface and Nanoparticles by a One-Step Method of Femtosecond Laser Ablation in a Hexane Solution

Molybdenum carbides (MoC and Mo2C) are being reported for various applications, for example, catalysts for sustainable energies, nonlinear materials for laser applications, protective coatings for improving tribological performance, and so on. A one-step method for simultaneously fabricating molybdenum monocarbide (MoC) nanoparticles (NPs) and MoC surfaces with a laser-induced periodic surface structure (LIPSS) was developed by using pulsed laser ablation of a molybdenum (Mo) substrate in hexane. Spherical NPs with an average diameter of 61 nm were observed by scanning electron microscopy. The X-ray diffraction pattern and electron diffraction (ED) pattern results indicate that a face-centered cubic MoC was successfully synthesized for the NPs and on the laser-irradiated area. Notably, the ED pattern suggests that the observed NPs are nanosized single crystals, and a carbon shell was observed on the surface of MoC NPs. The X-ray diffraction pattern of both MoC NPs and LIPSS surface indicates the formation of FCC MoC, agreeing with the results of ED. The results of X-ray photoelectron spectroscopy also showed the bonding energy attributed to Mo-C, and the sp2-sp3 transition was confirmed on the LIPSS surface. The results of Raman spectroscopy have also supported the formation of MoC and amorphous carbon structures. This simple synthesis method for MoC may provide new possibilities for preparing Mo x C-based devices and nanomaterials, which may contribute to the development of catalytic, photonic, and tribological fields.

Recent advances in understanding and design of efficient hydrogen evolution electrocatalysts for water splitting: A comprehensive review

An unsustainable reliance on fossil fuels is the primary cause of the vast majority of greenhouse gas emissions, which in turn lead to climate change. Green hydrogen (H₂), which may be generated by electrolyzing water with renewable power sources, is a possible substitute for fossil fuels. On the other hand, the increasing intricacy of hydrogen evolution electrocatalysts that are presently being explored makes it more challenging to integrate catalytic theories, catalytic fabrication procedures, and characterization techniques. This review will initially present the thermodynamics, kinetics, and associated electrical and structural characteristics for HER electrocatalysts before highlighting design approaches for the electrocatalysts. Secondly, an in-depth discussion regarding the rational design, synthesis, mechanistic insight, and performance improvement of electrocatalysts is centered on both the intrinsic and extrinsic influences. Thirdly, the most recent technological advances in electrocatalytic water-splitting approaches are described. Finally, the difficulties and possibilities associated with generating extremely effective HER electrocatalysts for water-splitting applications are discussed.

Pt-Based Nanostructures for Electrochemical Oxidation of CO: Unveiling the Effect of Shapes and Electrolytes

Direct alcohol fuel cells are deemed as green and sustainable energy resources; however, CO-poisoning of Pt-based catalysts is a critical barrier to their commercialization. Thus, investigation of the electrochemical CO oxidation activity (COOxid) of Pt-based catalyst over pH ranges as a function of Pt-shape is necessary and is not yet reported. Herein, porous Pt nanodendrites (Pt NDs) were synthesized via the ultrasonic irradiation method, and its CO oxidation performance was benchmarked in different electrolytes relative to 1-D Pt chains nanostructure (Pt NCs) and commercial Pt/C catalyst under the same condition. This is a trial to confirm the effect of the size and shape of Pt as well as the pH of electrolytes on the COOxid. The COOxid activity and durability of Pt NDs are substantially superior to Pt NCs and Pt/C in HClO4, KOH, and NaHCO3 electrolytes, respectively, owing to the porous branched structure with a high surface area, which maximizes Pt utilization. Notably, the COOxid performance of Pt NPs in HClO4 is higher than that in NaHCO3, and KOH under the same reaction conditions. This study may open the way for understanding the COOxid activities of Pt-based catalysts and avoiding CO-poisoning in fuel cells.

Activity Quantification of Fuel Cell Catalysts via Sequential Poisoning by Multiple Reaction Inhibitors

The development of non-Pt or carbon-based catalysts for anion exchange membrane fuel cells (AEMFCs) requires identification of the active sites of the catalyst. Since not only metals but also carbon materials exhibit oxygen reduction reaction (ORR) activity in alkaline conditions, the contribution of carbon-based materials to ORR performance should also be thoroughly analyzed. However, the conventional CN^- poisoning experiments, which are mainly used to explain the main active site of M-N-C catalysts, are limited to only qualitative discussions, having the potential to make fundamental errors. Here, we report a modified electrochemical analysis to quantitatively investigate the contribution of the metal and carbon active sites to ORR currents at a fixed potential by sequentially performing chronoamperometry with two reaction inhibitors, CN^- and benzyl trimethylammonium (BTMA⁺). As a result, we discover how to quantify the individual contributions of two active sites (Pt nanoparticles and carbon support) of carbon-supported Pt (Pt/C) nanoparticles as a model catalyst. This study is expected to provide important clues for the active site analysis of carbon-supported non-Pt catalysts, such as M-N-C catalysts composed of heterogeneous elements.

Trimetallic Nanoalloy of NiFeCo Embedded in Phosphidated Nitrogen Doped Carbon Catalyst for Efficient Electro-Oxidation of Kraft Lignin

Recently, electro-oxidation of kraft lignin has been reported as a prominent electrochemical reaction to generate hydrogen at lower overpotential in alkaline water electrolysis. However, this reaction is highly limited by the low performance of existing electrocatalysts. Herein, we report a novel yet effective catalyst that comprises nonprecious trimetallic (Ni, Fe, and Co) nanoalloy as a core in a phosphidated nitrogen-doped carbon shell (referred to as sample P-NiFeCo/NC) for efficient electro-oxidation of kraft lignin at different temperatures in alkaline medium. The as-synthesized catalyst electro-oxidizes lignin only at 0.2 V versus Hg/HgO, which is almost three times less positive potential than in the conventional oxygen evolution reaction (0.59 V versus Hg/HgO) at 6.4 mA/cm² in 1 M KOH. The catalyst demonstrates a turnover frequency (TOF) three to five times greater in lignin containing 1 M KOH than that of pure 1 M KOH. More importantly, the catalyst P-NiFeCo/NC shows theoretical hydrogen production of about 0.37 μmoles/min in the presence of lignin, much higher than that in pure 1 M KOH (0.0078 μ moles/min). Thus, this work verifies the benefit of the NiFeCo nanoalloy incorporated in carbon matrix, providing the way to realize a highly active catalyst for the electro-oxidation of kraft lignin.

Carbon Shell on Active Nanocatalyst for Stable Electrocatalysis

Electrocatalysis is a key process for renewable energy conversion and fuel production in future energy systems. Various nanostructures have been investigated to optimize the electrocatalytic activity and realize efficient energy use. However, the long-term stability of electrocatalysts is also crucial for the sustainable and reliable operation of energy devices. Nanocatalysts are degraded by various processes during electrocatalysis, which causes critical performance loss. Recent operando analyses have revealed the mechanisms of electrocatalyst failure, and specific structures have been identified as robust against degradation. Nevertheless, achieving both high activity and robust stability with the same nanostructure is challenging because the structure-property relationships that affect activity and stability are different. The optimization of electrocatalysis is often limited by a large trade-off between activity and stability in catalyst structures. Therefore, it is essential to introduce functional structural units into catalyst design to achieve electrochemical stability while preserving high activity.In this Account, we highlight the strategic use of carbon shells on catalyst surfaces to improve the stability during electrocatalysis. For this purpose, we cover three issues in the use of carbon-shell-encapsulated nanoparticles (CSENPs) as robust and active electrocatalysts: the origin of the improved stability, the identification of active sites, and synthetic routes. Carbon shells can shield catalyst surfaces from both (electro)chemical oxidation and physical agglomeration. By limiting the exposure of the catalyst surface to an oxidizing (electro)chemical environment, carbon shells can preserve the initial active site structure during electrocatalysis. In addition, by providing a physical barrier between nanoparticles, carbon shells can maintain the high surface area of CSENPs by reducing particle agglomeration during electrocatalysis. This barrier effect is also useful for constructing more active or durable structures by annealing without surface area loss. Compared to the clear stabilizing effect, however, the effect of the shell on active sites on the CSENP surface can be puzzling. Even when they are covered by a carbon shell that can block molecular adsorption on active sites, CSENP catalysts remain active and even exhibit unique catalytic behavior. Thus, we briefly cover recent efforts to identify major active sites on CSENPs using molecular probes. Furthermore, considering the membranelike role of the carbon shell, we suggest several remaining issues that should be resolved to obtain a fundamental understanding of CSENP design. Finally, we describe two synthetic approaches for the successful carbon shell encapsulation of nanoparticles: two-step and one-step syntheses. Both the postmortem coating of nanocatalysts (two-step) and the in situ formation via precursor ligands (one step) are shown to produce a durable carbon layer on nanocatalysts in a controlled manner. The strengths and limitations of each approach are also presented to promote the further investigation of advanced synthesis methods.The hybrid structure of CSENPs, that is, the active catalyst surface and the durable carbon shell, provides an interesting opportunity in electrocatalysis. However, our understanding of CSENPs is still highly limited, and further investigation is needed to answer fundamental questions regarding both active site identification and the mechanisms of stability improvement. Only when we start to comprehend the fundamental mechanisms underlying electrocatalysis on CSENPs will electrocatalysts be further improved for sustainable long-term device operation.

Ruthenium nanoparticles supported on S-doped graphene as an efficient HER electrocatalyst

An efficient HER catalyst was prepared by doping graphene and wrapping ruthenium nanoparticles, and its performance is comparable to that of commercial Pt/C.