Effect of Electronic Conductivities of Iridium Oxide/Doped SnO2 Oxygen-Evolving Catalysts on the Polarization Properties in Proton Exchange Membrane Water Electrolysis

Impact of Nickel on Iridium-Ruthenium Structure and Activity for the Oxygen Evolution Reaction under Acidic Conditions

Proton exchange membrane water electrolysis (PEMWE) is a promising technology to produce hydrogen directly from renewable electricity sources due to its high power density and potential for dynamic operation. Widespread application of PEMWE is, however, currently limited due to high cost and low efficiency, for which high loading of expensive iridium catalyst and high OER overpotential, respectively, are important reasons. In this study, we synthesize highly dispersed IrRu nanoparticles (NPs) supported on antimony-doped tin oxide (ATO) to maximize catalyst utilization. Furthermore, we study the effect of adding various amounts of Ni to the synthesis, both in terms of catalyst structure and OER activity. Through characterization using various X-ray techniques, we determine that the presence of Ni during synthesis yields significant changes in the structure of the IrRu NPs. With no Ni present, metallic IrRu NPs were synthesized with Ir-like structure, while the presence of Ni leads to the formation of IrRu oxide particles with rutile/hollandite structure. There are also clear indications that the presence of Ni yields smaller particles, which can result in better catalyst dispersion. The effect of these differences on OER activity was also studied through rotating disc electrode measurements. The IrRu-supported catalyst synthesized with Ni exhibited OER activity of up to 360 mA mgPGM -1 at 1.5 V vs RHE. This is ∼7 times higher OER activity than the best-performing IrO x benchmark reported in the literature and more than twice the activity of IrRu-supported catalyst synthesized without Ni. Finally, density functional theory (DFT) calculations were performed to further elucidate the origin of the observed activity enhancement, showing no improvement in intrinsic OER activity for hollandite Ir and Ru compared to the rutile structures. We, therefore, hypothesize that the increased activity measured for the IrRu supported catalyst synthesized with Ni present is instead due to increased electrochemical surface area.

Macroporous Structures of Nb-SnO2 Particles as a Catalyst Support Induce High Porosity and Performance in Polymer Electrolyte Fuel Cell Catalyst Layers

Macroporous niobium-doped tin oxide (NTO) is introduced as a robust alternative to conventional carbon-based catalyst supports to improve the durability and performance of polymer electrolyte fuel cells (PEFCs). Metal oxides like NTO are more stable than carbon under PEFC operational conditions, but they can compromise gas diffusion and water management because of their denser structures. To address this tradeoff, we synthesized macroporous NTO particles using a flame-assisted spray-drying technique employing poly(methyl methacrylate) as a templating agent. X-ray diffraction analysis and scanning electron microscopy confirmed the preservation of crystallinity and revealed a macroporous morphology with larger pore volumes and diameters than those in flame-made NTO nanoparticles, as revealed by mercury porosimetry. The macroporous NTO particles exhibited enhanced maximum current density and reduced gas diffusion resistance relative to commercial carbon supports. Our findings establish a foundation for integrating macroporous NTO structures into PEFCs to optimize durability and performance.

Synthesis of a Mesoporous SnO2 Catalyst Support and the Effect of Its Pore Size on the Performance of Polymer Electrolyte Fuel Cells

The aim of this study was to clarify the effectiveness and challenges of applying mesoporous tin oxide (SnO2)-based supports for Pt catalysts in the cathodes of polymer electrolyte fuel cells (PEFCs) to simultaneously achieve high performance and high durability. Recently, the focus of PEFC application in automobiles has shifted to heavy-duty vehicles (HDVs), which require high durability, high energy-conversion efficiency, and high power density. It has been reported that employing mesoporous carbon supports improves the initial performance by mitigating catalyst poisoning caused by sulfonic acid groups of the ionomer as well as by reducing the oxygen transport resistance through the Pt/ionomer interface. However, carbon materials in the cathode can degrade oxidatively during long-term operation, and more stable materials are desired. In this study, we synthesized connected mesoporous Sb-doped tin oxides (CMSbTOs) with controlled mesopore sizes in the range of 4-11 nm and tested their performance and durability as cathode catalyst supports. The CMSbTO supports exhibited higher fuel cell performance at a pore size of 7.3 nm than the solid-core SnO2-based, solid-core carbon, and mesoporous carbon supports under dry conditions, which can be attributed to the mitigation of the formation of the Pt/ionomer interface and the better proton conductivity within the mesopores even at the low-humidity conditions. In addition, the CMSbTO supports exhibited high durability under oxidative conditions. These results demonstrate the promising applicability of mesoporous tin oxide supports in PEFCs for HDVs. The remaining challenges, including the requirements for improving performance under wet conditions and stability under reductive conditions, are also discussed.

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.

Nanotubular TiO x N y -Supported Ir Single Atoms and Clusters as Thin-Film Electrocatalysts for Oxygen Evolution in Acid Media

A versatile approach to the production of cluster- and single atom-based thin-film electrode composites is presented. The developed TiO _x N _y -Ir catalyst was prepared from sputtered Ti-Ir alloy constituted of 0.8 ± 0.2 at % Ir in α-Ti solid solution. The Ti-Ir solid solution on the Ti metal foil substrate was anodically oxidized to form amorphous TiO₂-Ir and later subjected to heat treatment in air and in ammonia to prepare the final catalyst. Detailed morphological, structural, compositional, and electrochemical characterization revealed a nanoporous film with Ir single atoms and clusters that are present throughout the entire film thickness and concentrated at the Ti/TiO _x N _y -Ir interface as a result of the anodic oxidation mechanism. The developed TiO _x N _y -Ir catalyst exhibits very high oxygen evolution reaction activity in 0.1 M HClO₄, reaching 1460 A g^-1 _Ir at 1.6 V vs reference hydrogen electrode. The new preparation concept of single atom- and cluster-based thin-film catalysts has wide potential applications in electrocatalysis and beyond. In the present paper, a detailed description of the new and unique method and a high-performance thin film catalyst are provided along with directions for the future development of high-performance cluster and single-atom catalysts prepared from solid solutions.

Understanding the microstructure of a core-shell anode catalyst layer for polymer electrolyte water electrolysis

Reducing precious metal loading in the anodic catalyst layer (CL) is indispensable for lowering capital costs and enabling the widespread adoption of polymer electrolyte water electrolysis. This work presents the first three-dimensional reconstruction of a TiO₂-supported IrO₂ based core shell CL (3 mg_IrO2/cm₂), using high-resolution X-ray ptychographic tomography at cryogenic temperature of 90 K. The high data quality and phase sensitivity of the technique have allowed the reconstruction of all four phases namely pore space, IrO₂, TiO₂ support matrix and the ionomer network, the latter of which has proven to be a challenge in the past. Results show that the IrO₂ forms thin nanoporous shells around the TiO₂ particles and that the ionomer has a non-uniform thickness and partially covers the catalyst. The TiO₂ particles do not form a percolating network while all other phases have high connectivity. The analysis of the CL ionic and electronic conductivity shows that for a dry CL, the ionic conductivity is orders of magnitudes lower than the electronic conductivity. Varying the electronic conductivity of the support phase by simulations, reveals that the conductivity of the support does not have a considerable impact on the overall CL electrical conductivity.

Iridium Stabilizes Ceramic Titanium Oxynitride Support for Oxygen Evolution Reaction

Decreasing iridium loading in the electrocatalyst presents a crucial challenge in the implementation of proton exchange membrane (PEM) electrolyzers. In this respect, fine dispersion of Ir on electrically conductive ceramic supports is a promising strategy. However, the supporting material needs to meet the demanding requirements such as structural stability and electrical conductivity under harsh oxygen evolution reaction (OER) conditions. Herein, nanotubular titanium oxynitride (TiON) is studied as a support for iridium nanoparticles. Atomically resolved structural and compositional transformations of TiON during OER were followed using a task-specific advanced characterization platform. This combined the electrochemical treatment under floating electrode configuration and identical location transmission electron microscopy (IL-TEM) analysis of an in-house-prepared Ir-TiON TEM grid. Exhaustive characterization, supported by density functional theory (DFT) calculations, demonstrates and confirms that both the Ir nanoparticles and single atoms induce a stabilizing effect on the ceramic support via marked suppression of the oxidation tendency of TiON under OER conditions.

Supported Iridium-based Oxygen Evolution Reaction Electrocatalysts - Recent Developments

The commercialization of acidic proton exchange membrane water electrolyzers (PEMWE) is heavily hindered by the price and scarcity of oxygen evolution reaction (OER) catalyst, i. e. iridium and its oxides. One of the solutions to enhance the utilization of this precious metal is to use a support to distribute well dispersed Ir nanoparticles. In addition, adequately chosen support can also impact the activity and stability of the catalyst. However, not many materials can sustain the oxidative and acidic conditions of OER in PEMWE. Hereby, we critically and extensively review the different materials proposed as possible supports for OER in acidic media and the effect they have on iridium performances.

Covalently Bonded Ir(IV) on Conducted Blue TiO2 for Efficient Electrocatalytic Oxygen Evolution Reaction in Acid Media

The stability of anode electrode has been a primary obstacle for the oxygen evolution reaction (OER) in acid media. We design Ir-oxygen of hydroxyl-rich blue TiO2 through covalent bonds (Ir–O2–2Ti) and investigate the outcome of favored exposure of different amounts of covalent Ir–oxygen linked to the conductive blue TiO2 in the acidic OER. The Ir-oxygen-blue TiO2 nanoclusters show a strong synergy in terms of improved conductivity and tiny amount usage of Ir by using blue TiO2 supporter, and enhanced stability using covalent Ir-oxygen-linking (i.e., Ir oxide) in acid media, leading to high acidic OER performance with a current density of 10 mA cm−2 at an overpotential of 342 mV, which is much higher than that of IrO2 at 438 mV in 0.1 M HClO4 electrolyte. Notably, the Ir–O2–2Ti has a great mass activity of 1.38 A/mgIr at an overpotential 350 mV, which is almost 27 times higher than the mass activity of IrO2 at the same overpotential. Therefore, our work provides some insight into non-costly, highly enhanced, and stable electrocatalysts for the OER in acid media.

IrW nanochannel support enabling ultrastable electrocatalytic oxygen evolution at 2 A cm-2 in acidic media

A grand challenge for proton exchange membrane electrolyzers is the rational design of oxygen evolution reaction electrocatalysts to balance activity and stability. Here, we report a support-stabilized catalyst, the activated ~200 nm-depth IrW nanochannel that achieves the current density of 2 A cm⁻² at an overpotential of only ~497 mV and maintains ultrastable gas evolution at 100 mA cm⁻² at least 800 h with a negligible degradation rate of ~4 μV h⁻¹. Structure analyses combined with theoretical calculations indicate that the IrW support alters the charge distribution of surface (IrO₂)_n clusters and effectively confines the cluster size within 4 (n≤4). Such support-stabilizing effect prevents the surface Ir from agglomeration and retains a thin layer of electrocatalytically active IrO₂ clusters on surface, realizing a win-win strategy for ultrahigh OER activity and stability. This work would open up an opportunity for engineering suitable catalysts for robust proton exchange membrane-based electrolyzers.

Although electrocatalytic water splitting can generating renewable fuels, it is challenging to find water oxidation catalysts that are stable in acid at high current densities. Here, authors explore IrW as oxygen evolution electrocatalysts maintaining high current densities for hundreds of hours.

Immobilization of Ir(OH)3 Nanoparticles in Mesospaces of Al-SiO2 Nanoparticles Assembly to Enhance Stability for Photocatalytic Water Oxidation

Iridium hydroxide (Ir(OH)3) nanoparticles exhibiting high catalytic activity for water oxidation were immobilized inside mesospaces of a silica-nanoparticles assembly (SiO2NPA) to suppress catalytic deactivation due to agglomeration. The Ir(OH)3 nanoparticles immobilized in SiO2NPA (Ir(OH)3/SiO2NPA) catalyzed water oxidation by visible light irradiation of a solution containing persulfate ion (S2O82−) and tris(2,2′-bipyridine)ruthenium(II) ion ([RuII(bpy)3]2+) as a sacrificial electron acceptor and a photosensitizer, respectively. The yield of oxygen (O2) based on the used amount of S2O82− was maintained over 80% for four repetitive runs using Ir(OH)3/SiO2NPA prepared by the co-accumulation method, although the yield decreased for the reaction system using Ir(OH)3/SiO2NPA prepared by the equilibrium adsorption method or Ir(OH)3 nanoparticles without SiO2NPA support under the same reaction conditions. Immobilization of Ir(OH)3 nanoparticles in Al3+-doped SiO2NPA (Al-SiO2NPA) results in further enhancement of the catalytic stability with the yield of more than 95% at the fourth run of the repetitive experiments.

Organometallic chemical deposition of crystalline iridium oxide nanoparticles on antimony-doped tin oxide support with high-performance for the oxygen evolution reaction

Organometallic chemical deposition (OMCD) of epitaxially anchored rutile IrO₂ nanoparticles on Sb-doped SnO₂ support, with high-performance towards the oxygen evolution reaction (OER).

Engineering Ternary Copper-Cobalt Sulfide Nanosheets as High-performance Electrocatalysts toward Oxygen Evolution Reaction

The rational design and development of the low-cost and effective electrocatalysts toward oxygen evolution reaction (OER) are essential in the storage and conversion of clean and renewable energy sources. Herein, a ternary copper-cobalt sulfide nanosheets electrocatalysts (denoted as CuCoS/CC) for electrochemical water oxidation has been synthesized on carbon cloth (CC) via the sulfuration of CuCo-based precursors. The obtained CuCoS/CC reveals excellent electrocatalytic performance toward OER in 1.0 M KOH. It exhibits a particularly low overpotential of 276 mV at current density of 10 mA cm−2, and a small Tafel slope (58 mV decade−1), which is superior to the current commercialized noble-metal electrocatalysts, such as IrO2. Benefiting from the synergistic effect of Cu and Co atoms and sulfidation, electrons transport and ions diffusion are significantly enhanced with the increase of active sites, thus the kinetic process of OER reaction is boosted. Our studies will serve as guidelines in the innovative design of non-noble metal electrocatalysts and their application in electrochemical water splitting

Ir nanoparticles with ultrahigh dispersion as oxygen evolution reaction (OER) catalysts: synthesis and activity benchmarking

In this work, we present a facile and straightforward approach to synthesize, activate and benchmark small, i.e. 1.6 nm in diameter, Ir nanoparticles (NP) as oxygen evolution reaction (OER) catalysts.