Recent advances in proton exchange membrane water electrolysis

Molybdenum, tungsten doped cobalt phosphides as efficient catalysts for coproduction of hydrogen and formate by glycerol electrolysis

H2 and formate are important energy carriers in fuel-cells and feedstocks in chemical industry. The hydrogen evolution reaction (HER) coupling with electro-oxidative cleavage of thermodynamically favorable polyols is a promising way to coproduce H2 and formate via electrochemical means, highly active catalysts for HER and electrooxidative cleavage of polycols are the key to achieve such a goal. Herein, molybdenum (Mo), tungsten (W) doped cobalt phosphides (Co2P) deposited onto nickel foam (NF) substrate, denoted as Mo-Co2P/NF and W-Co2P/NF, respectively, were investigated as catalytic electrodes for HER and electrochemical glycerol oxidation reaction (GOR) to yield H2 and formate. The W-Co2P/NF electrode exhibited low overpotential (η) of 113 mV to attain a current density (J) of -100 mA cm-2 for HER, while the Mo-Co2P/NF electrode demonstrated high GOR efficiency for selective production of formate. In situ Raman and infrared spectroscopic characterizations revealed that the evolved CoO2 from Co2P is the genuine catalytic sites for GOR. The asymmetric electrolyzer based on W-Co2P/NF cathode and Mo-Co2P/NF anode delivered a J = 100 mA cm-2 at 1.8 V voltage for glycerol electrolysis, which led to 18.2 % reduced electricity consumption relative to water electrolysis. This work highlights the potential of heteroelement doped phosphide in catalytic performances for HER and GOR, and opens up new avenue to coproduce more widespread commodity chemicals via gentle and sustainable electrocatalytic means.

Lanthanide-regulating Ru-O covalency optimizes acidic oxygen evolution electrocatalysis

Precisely modulating the Ru-O covalency in RuOx for enhanced stability in proton exchange membrane water electrolysis is highly desired. However, transition metals with d-valence electrons, which were doped into or alloyed with RuOx, are inherently susceptible to the influence of coordination environment, making it challenging to modulate the Ru-O covalency in a precise and continuous manner. Here, we first deduce that the introduction of lanthanide with gradually changing electronic configurations can continuously modulate the Ru-O covalency owing to the shielding effect of 5s/5p orbitals. Theoretical calculations confirm that the durability of Ln-RuOx following a volcanic trend as a function of Ru-O covalency. Among various Ln-RuOx, Er-RuOx is identified as the optimal catalyst and possesses a stability 35.5 times higher than that of RuO2. Particularly, the Er-RuOx-based device requires only 1.837 V to reach 3 A cm-2 and shows a long-term stability at 500 mA cm-2 for 100 h with a degradation rate of mere 37 μV h-1.

Heterointerface MnO2/RuO2 with rich oxygen vacancies for enhanced oxygen evolution in acidic media

The design and synthesis of oxygen evolution reaction (OER) electrocatalysts that operate efficiently and stably under acidic conditions are important for the preparation of green hydrogen energy. The low intrinsic catalytic activity and poor acid resistance of commercial RuO2 limit its further development, and the construction of heterointerface structures is the most promising strategy to break through the intrinsic activity limitation of electrocatalysts. Herein, we synthesized spherical and oxygen vacancy-rich heterointerface MnO2/RuO2 using morphology control, which promoted the kinetics of the oxygen evolution reaction with the interaction between oxygen vacancies and the oxide heterointerface. MnO2/RuO2 was reported to be an acidic OER catalyst with excellent performance and stability, requiring only an ultra-low overpotential of 181 mV in 0.5 M H2SO4 to achieve a current density of 10 mA cm-2. The catalyst activity remained essentially unchanged in a 140 h stability test with an ultra-high mass activity (858.9 A g-1@ 1.5 V), which was far superior to commercial RuO2 and most previously reported noble metal-based acidic OER catalysts. The experimental results showed that the effect of more oxygen vacancies and the heterointerfaces of manganese ruthenium oxides broke the intrinsic activity limitation, provided more active sites for the OER, accelerated reaction kinetics, and improved the stability of the catalyst. The excellent performance of the catalyst suggests that MnO2/RuO2 provides a new idea for the design and study of heterointerfaces in metal oxide nanomaterials.

Ultrathin Free-Standing Porous Aromatic Framework Membranes for Efficient Anion Transport

Porous aromatic frameworks (PAFs) show promising potential in anionic conduction due to their high stability and customizable functionality. However, the insolubility of most PAFs presents a significant challenge in their processing into membranes and subsequent applications. In this study, continuous PAF membranes with adjustable thickness were successfully created using liquid-solid interfacial polymerization. The rigid backbone and the stable C-C coupling endow PAF membrane with superior chemical and dimensional stabilities over most conventional polymer membranes. Different quaternary ammonium functionalities were anchored to the backbone through flexible alkyl chains with tunable length. The optimal PAF membrane exhibited an OH- conductivity of 356.6 mS ⋅ cm-1 at 80 °C and 98 % relative humidity. Additionally, the PAF membrane exhibited outstanding alkaline stability, retaining 95 % of its OH- conductivity after 1000 hours in 1 M NaOH. To the best of our knowledge, this is the first application of PAF materials in anion exchange membranes, achieving the highest OH- conductivity and exceptional chemical/dimensional stability. This work provides the possibility for the potential of PAF materials in anionic conductive membranes.

Interface-Engineered 3D porous MoS2-ReS2 in-plane heterojunction as efficient hydrogen evolution reaction electrocatalysts

Constructing in-plane heterojunctions with high interfacial density using two-dimensional materials represents a promising yet challenging avenue for enhancing the hydrogen evolution reaction (HER) in water electrolysis. In this work, we report that three-dimensional porous MoS2-ReS2 in-plane heterojunctions, fabricated via chemical vapor deposition, exhibit robust electrocatalytic activity for the water splitting reaction. The optimized MoS2-ReS2 in-plane heterojunction achieves superior HER performance across a wide pH range, requiring an overpotential of only 200 mV to reach a current density of 10 mA cm-2 in alkaline seawater. Thus, it outperforms standalone MoS2 and ReS2. Furthermore, the catalyst exhibits remarkable stability, enduring up to 200 h in alkaline seawater. Experimental results coupled with density functional theory calculations confirm that electron redistribution at the MoS2-ReS2 heterointerface is likely driven by disparities in in-plane work functions between the two phases. This leads to charge accumulation at the interface, thereby enhancing the adsorptive activity of S atoms toward H* intermediates and facilitating the dissociation of water molecules at the interface. This discovery offers valuable insights into the electrocatalytic mechanisms at the interface and provides a roadmap for designing high-performance, earth-abundant HER electrocatalysts suitable for practical applications.

Optimizing Ionomer Distribution in Anode Catalyst Layer for Stable Proton Exchange Membrane Water Electrolysis

The high cost of proton exchange membrane water electrolysis (PEMWE) originates from the usage of precious materials, insufficient efficiency, and lifetime. In this work, an important degradation mechanism of PEMWE caused by dynamics of ionomers over time in anode catalyst layer (ACL), which is a purely mechanical degradation of microstructure, is identified. Contrary to conventional understanding that the microstructure of ACL is static, the micropores are inclined to be occupied by ionomers due to the localized swelling/creep/migration, especially near the ACL/PTL (porous transport layer) interface, where they form transport channels of reactant/product couples. Consequently, the ACL with increased ionomers at PTL/ACL interface exhibit rapid and continuous degradation. In addition, a close correlation between the microstructure of ACL and the catalyst ink is discovered. Specifically, if more ionomers migrate to the top layer of the ink, more ionomers accumulate at the ACL/PEM interface, leaving fewer ionomers at the ACL/PTL interface. Therefore, the ionomer distribution in ACL is successfully optimized, which exhibits reduced ionomers at the ACL/PTL interface and enriches ionomers at the ACL/PEM interface, reducing the decay rate by a factor of three when operated at 2.0 A cm-2 and 80 °C. The findings provide a general way to achieve low-cost hydrogen production.

Chromium-Induced High Covalent Co-O Bonds for Efficient Anodic Catalysts in PEM Electrolyzer

The proton exchange membrane water electrolyzer (PEMWE), crucial for green hydrogen production, is challenged by the scarcity and high cost of iridium-based materials. Cobalt oxides, as ideal electrocatalysts for oxygen evolution reaction (OER), have not been extensively applied in PEMWE, due to extremely high voltage and poor stability at large current density, caused by complicated structural variations of cobalt compounds during the OER process. Thus, the authors sought to introduce chromium into a cobalt spinel (Co3O4) catalyst to regulate the electronic structure of cobalt, exhibiting a higher oxidation state and increased Co-O covalency with a stable structure. In-depth operando characterizations and theoretical calculations revealed that the activated Co-O covalency and adaptable redox behavior are crucial for facilitating its OER activity. Both turnover frequency and mass activity of Cr-doped Co3O4 (CoCr) at 1.67 V (vs RHE) increased by over eight times than those of as-synthesized Co3O4. The obtained CoCr catalyst achieved 1500 mA cm-2 at 2.17 V and exhibited notable durability over extended operation periods - over 100 h at 500 mA cm-2 and 500 h at 100 mA cm-2, demonstrating promising application in the PEMWE industry.

In Situ Electrochemical Rapid Induction of Highly Active γ-NiOOH Species for Industrial Anion Exchange Membrane Water Electrolyzer

Limited by the strong oxidation environment and sluggish reconstruction process in oxygen evolution reaction (OER), designing rapid self-reconstruction with high activity and stability electrocatalysts is crucial to promoting anion exchange membrane (AEM) water electrolyzer. Herein, trace Fe/S-modified Ni oxyhydroxide (Fe/S-NiOOH/NF) nanowires are constructed via a simple in situ electrochemical oxidation strategy based on precipitation-dissolution equilibrium. In situ characterization techniques reveal that the successful introduction of Fe and S leads to lattice disorder and boosts favorable hydroxyl capture, accelerating the formation of highly active γ-NiOOH. The Density Functional Theory (DFT) calculations have also verified that the incorporation of Fe and S optimizes the electrons redistribution and the d-band center, decreasing the energy barrier of the rate-determining step (*O→*OOH). Benefited from the unique electronic structure and intermediate adsorption, the Fe/S-NiOOH/NF catalyst only requires the overpotential of 345 mV to reach the industrial current density of 1000 mA cm-2 for 120 h. Meanwhile, assembled AEM water electrolyzer (Fe/S-NiOOH//Pt/C-60 °C) can deliver 1000 mA cm-2 at a cell voltage of 2.24 V, operating at the average energy efficiency of 71% for 100 h. In summary, this work presents a rapid self-reconstruction strategy for high-performance AEM electrocatalysts for future hydrogen economy.

Bifunctional Electrocatalysts for Overall and Hybrid Water Splitting

Electrocatalytic water splitting driven by renewable electricity has been recognized as a promising approach for green hydrogen production. Different from conventional strategies in developing electrocatalysts for the two half-reactions of water splitting (e.g., the hydrogen and oxygen evolution reactions, HER and OER) separately, there has been a growing interest in designing and developing bifunctional electrocatalysts, which are able to catalyze both the HER and OER. In addition, considering the high overpotentials required for OER while limited value of the produced oxygen, there is another rapidly growing interest in exploring alternative oxidation reactions to replace OER for hybrid water splitting toward energy-efficient hydrogen generation. This Review begins with an introduction on the fundamental aspects of water splitting, followed by a thorough discussion on various physicochemical characterization techniques that are frequently employed in probing the active sites, with an emphasis on the reconstruction of bifunctional electrocatalysts during redox electrolysis. The design, synthesis, and performance of diverse bifunctional electrocatalysts based on noble metals, nonprecious metals, and metal-free nanocarbons, for overall water splitting in acidic and alkaline electrolytes, are thoroughly summarized and compared. Next, their application toward hybrid water splitting is also presented, wherein the alternative anodic reactions include sacrificing agents oxidation, pollutants oxidative degradation, and organics oxidative upgrading. Finally, a concise statement on the current challenges and future opportunities of bifunctional electrocatalysts for both overall and hybrid water splitting is presented in the hope of guiding future endeavors in the quest for energy-efficient and sustainable green hydrogen production.

Efficient bubble/precipitate traffic enables stable seawater reduction electrocatalysis at industrial-level current densities

Seawater electroreduction is attractive for future H2 production and intermittent energy storage, which has been hindered by aggressive Mg2+/Ca2+ precipitation at cathodes and consequent poor stability. Here we present a vital microscopic bubble/precipitate traffic system (MBPTS) by constructing honeycomb-type 3D cathodes for robust anti-precipitation seawater reduction (SR), which massively/uniformly release small-sized H2 bubbles to almost every corner of the cathode to repel Mg2+/Ca2+ precipitates without a break. Noticeably, the optimal cathode with built-in MBPTS not only enables state-of-the-art alkaline SR performance (1000-h stable operation at -1 A cm-2) but also is highly specialized in catalytically splitting natural seawater into H2 with the greatest anti-precipitation ability. Low precipitation amounts after prolonged tests under large current densities reflect genuine efficacy by our MBPTS. Additionally, a flow-type electrolyzer based on our optimal cathode stably functions at industrially-relevant 500 mA cm-2 for 150 h in natural seawater while unwaveringly sustaining near-100% H2 Faradic efficiency. Note that the estimated price (~1.8 US$/kgH2) is even cheaper than the US Department of Energy's goal price (2 US$/kgH2).

Constructing Robust 3D Ionomer Networks in the Catalyst Layer to Achieve Stable Water Electrolysis for Green Hydrogen Production

The widespread application of proton exchange membrane water electrolyzers (PEMWEs) is hampered by insufficient lifetime caused by degradation of the anode catalyst layer (ACL). Here, an important degradation mechanism has been identified, attributed to poor mechanical stability causing the mass transfer channels to be blocked by ionomers under operating conditions. By using liquid-phase atomic force microscopy, we directly observed that the ionomers were randomly distributed (RD) in the ACL, which occupied the mass transfer channels due to swelling, creeping, and migration properties. Interestingly, we found that alternating treatments of the ACL in different water/temperature environments resulted in forming three-dimensional ionomer networks (3D INs) in the ACL, which increased the mechanical strength of microstructures by 3 times. Benefitting from the efficient and stable mass transfer channels, the lifetime was improved by 19 times. A low degradation rate of approximately 3.0 μV/h at 80 °C and a high current density of 2.0 A/cm2 was achieved on a 50 cm2 electrolyzer. These data demonstrated a forecasted lifetime of 80 000 h, approaching the 2026 DOE lifetime target. This work emphasizes the importance of the mechanical stability of the ACL and offers a general strategy for designing and developing a durable PEMWE.

Simultaneously improving the pore structure and electron conductive network of the anode catalyst layer via SnO2 doping for proton exchange membrane water electrolysis

Proton exchange membrane water electrolysis (PEMWE) is a promising technology for green hydrogen production. However, its large-scale commercial application is limited by its high precious metal loading, because low catalyst loading leads to reduced electron transport channels and decreased water transportation, etc. Herein, we study the electrode level strategy for reducing Ir loading by the optimization of the micro-structure of the anode catalyst layer via SnO2 doping. The pore structure and electron conductive network of the anode catalyst layer can be simultaneously improved by SnO2 doping, under appropriate conditions. Therefore, mass transfer polarization and ohmic polarization of the single cell are reduced. Moreover, the enhanced pore structure and improved electron conduction network collectively contribute to a decreased occurrence of charge transfer polarization. By this strategy, the performance of the single cell with the Ir loading of 1.5 mg cm-2 approaches the single cell with the higher Ir loading of 2.0 mg cm-2, which means that SnO2 doping saves about 25% loading of Ir. This paper provides a perspective at the electrode level to reduce the precious metal loading of the anode in PEMWE.

Nickel Hydroxide-Based Electrocatalysts for Promising Electrochemical Oxidation Reactions: Beyond Water Oxidation

Transition metal hydroxides have attracted significant research interest for their energy storage and conversion technique applications. In particular, nickel hydroxide (Ni(OH)2 ), with increasing significance, is extensively used in material science and engineering. The past decades have witnessed the flourishing of Ni(OH)2 -based materials as efficient electrocatalysts for water oxidation, which is a critical catalytic reaction for sustainable technologies, such as water electrolysis, fuel cells, CO2 reduction, and metal-air batteries. Coupling the electrochemical oxidation of small molecules to replace water oxidation at the anode is confirmed as an effective and promising strategy for realizing the energy-saving production. The physicochemical properties of Ni(OH)2 related to conventional water oxidation are first presented in this review. Then, recent progress based on Ni(OH)2 materials for these promising electrochemical reactions is symmetrically categorized and reviewed. Significant emphasis is placed on establishing the structure-activity relationship and disclosing the reaction mechanism. Emerging material design strategies for novel electrocatalysts are also highlighted. Finally, the existing challenges and future research directions are presented.

Proton-Conducting Membranes from Polyphenylenes Containing Armstrong's Acid

This study demonstrates the use of 1,5-naphthalenedisulfonic acid as a suitable building block for the efficient and economic preparation of alternating sulfonated polyphenylenes with high ion-exchange capacity (IEC) via Suzuki polycondensation. Key to large molar masses is the use of an all-meta-terphenyl comonomer instead of m-phenyl, the latter giving low molar masses and brittle materials. A protection/deprotection strategy for base-stable neopentyl sulfonates is successfully implemented to improve the solubility and molar mass of the polymers. Solution-based deprotection of polyphenylene neopentyl sulfonates at 150 °C in dimethylacetamide eliminates isopentylene quantitatively, resulting in membranes with high IEC (2.93 mequiv/g) and high proton conductivity (σ = 138 mS/cm). Water solubility of these copolymers with high IEC requires thermal cross-linking to prevent their dissolution under operating conditions. By balancing the temperature and time of the cross-linking process, water uptake can be restricted to 50 wt %, retaining an IEC of 2.33 mequiv/g and a conductivity of 85 mS/cm. Chemical stability is addressed by treatment of the membranes under Fenton's conditions and by considering barrier heights for desulfonation using density functional theory (DFT) calculations. The DFT results suggest that 1,5-disulfonated naphthalenes are at least as stable as sulfonated polyphenylenes against desulfonation.

RuO2 Catalysts for Electrocatalytic Oxygen Evolution in Acidic Media: Mechanism, Activity Promotion Strategy and Research Progress

Proton Exchange Membrane Water Electrolysis (PEMWE) under acidic conditions outperforms alkaline water electrolysis in terms of less resistance loss, higher current density, and higher produced hydrogen purity, which make it more economical in long-term applications. However, the efficiency of PEMWE is severely limited by the slow kinetics of anodic oxygen evolution reaction (OER), poor catalyst stability, and high cost. Therefore, researchers in the past decade have made great efforts to explore cheap, efficient, and stable electrode materials. Among them, the RuO2 electrocatalyst has been proved to be a major promising alternative to Ir-based catalysts and the most promising OER catalyst owing to its excellent electrocatalytic activity and high pH adaptability. In this review, we elaborate two reaction mechanisms of OER (lattice oxygen mechanism and adsorbate evolution mechanism), comprehensively summarize and discuss the recently reported RuO2-based OER electrocatalysts under acidic conditions, and propose many advanced modification strategies to further improve the activity and stability of RuO2-based electrocatalytic OER. Finally, we provide suggestions for overcoming the challenges faced by RuO2 electrocatalysts in practical applications and make prospects for future research. This review provides perspectives and guidance for the rational design of highly active and stable acidic OER electrocatalysts based on PEMWE.

Bubbles in Porous Electrodes for Alkaline Water Electrolysis

Porous electrodes with high specific surface areas have been commonly employed for alkaline water electrolysis. The gas bubbles generated in electrodes due to water electrolysis, however, can screen the reaction sites and hinder reactant transport, thereby deteriorating the performance of electrodes. Hence, an in-depth understanding of the behavior of bubbles in porous electrodes is of great importance. Nevertheless, since porous electrodes are opaque, direct observation of bubbles therein is still a challenge. In this work, we have successfully captured the behavior of bubbles in the pores at the side surfaces of nickel-based porous electrodes. Two types of porous electrodes are employed: the ones with straight pores along the gravitational direction and the ones with tortuous pores. In the porous electrodes with tortuous pores, the moving bubbles are prone to collide with the solid matrix, thereby leading to the accumulation of bubbles in the pores and hence bubble trapping. By contrast, in the porous electrodes with straight pores, bubbles are seldom trapped; and when two bubbles near the wall surfaces coalesce, the merged bubble can jump away from the wall surfaces, releasing more active surfaces for reaction. As a result, the porous electrodes with straight pores, although with lower specific surface areas, are superior to those with tortuous pores. The relationship among the pore structures of porous electrodes, bubble behavior, and electrode performance disclosed in this work provides deep insights into the design of porous electrodes.

Review on Bubble Dynamics in Proton Exchange Membrane Water Electrolysis: Towards Optimal Green Hydrogen Yield

Water electrolysis using a proton exchange membrane (PEM) holds substantial promise to produce green hydrogen with zero carbon discharge. Although various techniques are available to produce hydrogen gas, the water electrolysis process tends to be more cost-effective with greater advantages for energy storage devices. However, one of the challenges associated with PEM water electrolysis is the accumulation of gas bubbles, which can impair cell performance and result in lower hydrogen output. Achieving an in-depth knowledge of bubble dynamics during electrolysis is essential for optimal cell performance. This review paper discusses bubble behaviors, measuring techniques, and other aspects of bubble dynamics in PEM water electrolysis. It also examines bubble behavior under different operating conditions, as well as the system geometry. The current review paper will further improve the understanding of bubble dynamics in PEM water electrolysis, facilitating more competent, inexpensive, and feasible green hydrogen production.