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Guided by computational Pourbaix screening and high-throughput experiments aimed at the development of precious-metal-free fuel cells, we investigate rutile CoSb₂O₆ as an electrocatalyst for oxygen reduction in 1 M sulfuric acid. Following 4 h of catalyst conditioning at 0.7 V vs RHE, operation at this potential for 20 h yielded an average current density of −0.17 mA cm⁻² with corrosion at a rate of 0.04 nm hour⁻¹ that is stoichiometric with catalyst composition. Surface Pourbaix analysis of the (111) surface identified partial H coverage under operating conditions. The Sb active site has an HO* binding free energy of 0.49 eV, which is near the peak of the kinetic 4e⁻ ORR volcano for transition-metal oxides in acidic conditions. The experimental demonstration of operational stability and computational identification of a reaction pathway with favorable energetics place rutile CoSb₂O₆ among the most promising precious-metal-free electrocatalysts for oxygen reduction in acidic media.

The oxygen evolution reaction (OER) is central to several sustainable energy technologies. Catalyst development has largely focused on lowering the overpotential and eliminating reliance on precious metals, revealing stark differences in alkaline and acidic OER. In alkaline electrolyte, precious metal-free catalysts have approached the limiting overpotential from established free energy scaling relationships, and our survey of complex metal oxides shows that this limit can be approached with a broad range of catalysts. In acidic electrolyte, electrochemical instabilities create a dual challenge of a dearth of nonprecious metal OER catalysts with overpotential below 0.5 V and a high dissolved metals concentration for most precious metal-free catalysts. On device-relevant time scales, the high dissolved metals concentrations compromise device stability, for example, through a decrease of performance and due to metal exchange between anode and cathode catalysts due to finite permeability of ion exchange membranes. These considerations motivate a substantial increase in monitoring and reporting of dissolved metals concentrations in OER experiments. To facilitate durability-based screening in continued catalyst discovery campaigns, we introduce a durability descriptor based on the d-electron count of each metal element compared to that of its Pourbaix-stable oxidation state, which enables rapid down-selection of candidate metal oxide catalysts. We discuss the importance of a codesign approach to catalyst development, where a device architecture can set specific requirements for dissolved metals concentrations and/or cathode and anode catalysts can be designed to tolerate cross-contamination. This device-level guidance of basic science will facilitate deployment of new catalysts to meet the societal needs for accelerated sustainable technology development.

The hydrodynamics of electrochemical CO2 reduction (CO2R) systems is an insufficiently investigated area of research that has broad implications on catalyst activity and selectivity. While most previous reports are limited to laminar and CO2-sparged systems, herein we address a wide range of hydrodynamics via electrolyte recirculation systems. We find that increased hydrodynamics at the electrode surface results directly in changes to the ethylene and methane Tafel slopes, demonstrating that mass transport is on equal footing with catalyst active sites in determining reaction mechanisms and the ensuing product distribution. Mass transport is traditionally considered to be in the purview of systems-level engineering, yet the present work shows that CO2R mechanistic work must be considered in the context of the mass transport conditions. We extend our analysis to organic coatings, demonstrating that the films shield the active sites from variability in hydrodynamics and increase the residence time of CO so that it may be further reduced to desirable products.

Boundary conditions for catalyst performance in the conversion of common precursors such as N2, O2, H2O, and CO2 are governed by linear free energy and scaling relationships. Knowledge of these limits offers an impetus for designing strategies to alter reaction mechanisms to improve performance. Typically, experimental demonstrations of linear trends and deviations from them are composed of a small number of data points constrained by inherent experimental limitations. Herein, high-throughput experimentation on 14 bulk copper bimetallic alloys allowed for data-driven identification of a scaling relationship between the partial current densities of methane and C2+ products. This strict dependence represents an intrinsic limit to the Faradaic efficiency for C–C coupling. We have furthermore demonstrated that coating the electrodes with a molecular film breaks the scaling relationship to promote C2+ product formation., High-throughput experimentation on the reduction of CO2 on copper alloys led to the identification of a scaling relationship between CH4 and C2+ products that can be broken with an organic additive.

Summary We report an active zinc-copper (Zn-Cu) bimetallic electrocatalyst for CO2 reduction to CO, prepared by a facile galvanic procedure. Under moderate overpotentials, Zn-Cu catalysts that are Zn rich exhibit intrinsic activity for CO formation superior to that of pure Zn, Cu, and Ag, the last of which is the state-of-the-art catalyst in CO2 electrolyzers. Combinatorial experiments involving catalysts prepared by physical vapor deposition reveal trends across the Zn-Cu system, corroborating the high CO selectivity unrivaled by other alloys and intermetallics. Physical and electrochemical characterization and first principles theory reveal that the origin of this synergy in intrinsic activity is an electronic effect from bimetallic Zn-Cu sites that stabilizes the carboxyl intermediate during CO2 reduction to CO. Furthermore, by integrating Zn-Cu into gas-diffusion electrodes, we demonstrate that bimetallic effects lead to improved electrocatalytic performance at industrially relevant currents. These insights provide catalyst design principles that can guide future development of efficient and earth-abundant CO-producing electrocatalysts.

Renewable generation of fuels using solar energy is a promising technology whose deployment hinges on the discovery of materials with a combination of durability and solar-to-chemical conversion efficiency that has yet to be demonstrated. Stable operation of photoanodes has been demonstrated with wide-gap semiconductors, as well as protected visible gap semiconductors. Visible photoresponse from electrochemically stable materials is quite rare. In this paper, we report the high-throughput discovery of an amorphous Ni-Sb (1:1) oxide photoanode that meets the requirements of operational stability, visible photoresponse, and appreciable photovoltage. X-ray absorption characterization of Ni and Sb establishes a structural connection to rutile NiSb₂O₆, guiding electronic structure characterization via X-ray photoelectron experiments and density functional theory. This amorphous photoanode opens avenues for photoelectrode development due to the lack of crystal anisotropy combined with its operational stability, which mitigates the formation of an interphase that disrupts the semiconductor-electrolyte junction.

Summary Copper vanadates are a promising class of solar fuel photoanodes with broad spectral response and excellent operational stability. The present performance limitations of these photoanodes are most evident in the rapid decrease in photoactivity with decrease in either photon energy or applied bias, the former limiting efficient utilization of the solar spectrum and the latter limiting photovoltage. We designed high-throughput photoelectrochemical screening to characterize these two aspects of improving Cu-V-based photoanodes in quaternary oxide composition spaces of the form Cu-V-X-O, where X = Mg, Ca, Sr, Fe. The results reveal that alloying of 2+ cations onto the Cu site of copper vanadates can improve photoelectrochemical properties, and Sr-alloyed Cu5V2O10 emerges as the most promising photoanode providing the best combination of photovoltage and spectral response. Six quaternary oxide phases are discovered as photoanodes with visible light activity below 1.23 V versus reversible hydrogen electrode, highlighting the high-throughput photoanode discovery.

Electrochemical CO2 reduction to valuable products is a centerpiece of future energy technologies that relies on identificaiton of new catalysts. We present accelerated screening of Cu bimetallic alloys, revealing remarkable sensitivity to alloy concentration that indicates the segregation of alloying elements to critical sites for hydrocarbon formation.

Electrochemical conversion of carbon dioxide into valuable chemicals or fuels is an increasingly important strategy for achieving carbon neutral technologies. The lack of a sufficiently active and selective electrocatalyst, particularly for synthesizing highly reduced products, motivates accelerated screening to evaluate new catalyst spaces. Traditional techniques, which couple electrocatalyst operation with analytical techniques to measure product distributions, enable screening throughput at 1-10 catalysts per day. In this paper, a combinatorial screening instrument is designed for MS detection of hydrogen, methane, and ethylene in quasi-real-time during catalyst operation experiments in an electrochemical flow cell. Coupled with experiment modeling, product detection during cyclic voltammetry (CV) enables modeling of the voltage-dependent partial current density for each detected product. We demonstrate the technique by using the well-established thin film Cu catalysts and by screening a Pd-Zn composition library in carbonate-buffered aqueous electrolyte. The rapid product distribution characterization over a large range of overpotential makes the instrument uniquely suited for accelerating screening of electrocatalysts for the carbon dioxide reduction reaction.

The nature of the active species in Zn-containing HZSM-5 catalysts was investigated by preparing Zn-HZSM-5 via three different synthetic approaches: wet ion exchange, wet impregnation, and core–shell synthesis. By investigating the impact of the preparation methods on the distribution of Zn species, and studying the catalytic performance of the resulting materials in methane dehydroaromatization (DHA), it was shown that metallic Zn0 nanoclusters inside the zeolite micropore constituted the most active species for DHA, but get irreversible loss from the catalyst via evaporation at the high-temperature conditions of DHA. In contrast, Zn2+ anchored at the exchange sites of the zeolite were the most stable species, but provided little to no aromatization activity. As a result, and counter to previous reports in the literature, it was concluded that Zn/HZSM-5 was not a suitable catalyst for non-oxidative methane dehydroaromatization. Nonetheless, the study confirmed that well-dispersed metal species inside the zeolitic micropores were critical for aromatization activity of zeolite-based catalysts. © 2016 American Institute of Chemical Engineers Environ Prog, 2016

Conversion of natural gas to aromatics via non-oxidative dehydroaromatization (DHA) is a promising route to replace oil with a cheap and abundant domestic resource as feed-stock for the petrochemical industry. However, the reaction is still lacking a suitable catalyst system to-date. We present results from a study into the nature of the active species in Fe-containing HZSM-5 catalysts through the preparation of Fe-HZSM-5 via three different synthetic approaches: isomorphous substitution, wet ion exchange, and core–shell synthesis. By carefully investigating the impact of the preparation methods on the distribution of Fe species, and studying the catalytic performance of the resulting materials in methane DHA, we show that coking is reduced with increasing Fe dispersion and that highly (atomically) dispersed Fe2+ inside the zeolite micropores constitutes the selective species for DHA. However, the presence of Bronsted acid sites in the zeolite micropores results in continued coke formation due to secondary reactions of the aromatic product. Further optimization of the catalyst hence requires careful adjustment of this acidity.

Identifying new catalyst materials for complex reactions such as the electrochemical reduction of CO_2 poses substantial instrumentation challenges due to the need to integrate reactor control with electrochemical and analytical instrumentation. Performing accelerated screening to enable exploration of a broad span of catalyst materials poses additional challenges due to the long time scales associated with accumulation of reaction products and the detection of the reaction products with traditional separation-based analytical methods. The catalyst screening techniques that have been reported for combinatorial studies of (photo)electrocatalysts do not meet the needs of CO_2 reduction catalyst research, prompting our development of a new electrochemical cell design and its integration to gas and liquid chromatography instruments. To enable rapid chromatography measurements while maintaining sensitivity to minor products, the electrochemical cell features low electrolyte and head space volumes compared to the catalyst surface area. Additionally, the cell is operated as a batch reactor with electrolyte recirculation to rapidly concentrate reaction products, which serves the present needs for rapidly detecting minor products and has additional implications for enabling product separations in industrial CO_2 electrolysis systems. To maintain near-saturation of CO_2 in aqueous electrolytes, we employ electrolyte nebulization through a CO_2-rich headspace, achieving similar gas-liquid equilibration as vigorous CO_2 bubbling but without gas flow. The instrument is demonstrated with a series of electrochemical experiments on an Au-Pd combinatorial library, revealing non-monotonic variations in product distribution with respect to catalyst composition. The highly integrated analytical electrochemistry system is engineered to enable automation for rapid catalyst screening as well as deployment for a broad range of electrochemical reactions where product distribution is critical to the assessment of catalyst performance.

Separating oil from saltwater is a process relevant to some industries and may be aided by bubble and froth generation. Simulating saltwater-air interfaces adsorbed with surfactants and oil molecules can assist in understanding froth stability to improve separation. Combining with surface tension experimental measurements, in this work we employ molecular dynamics with a united-atom force field to linear alkane oil and three surfactant frothers, methyl isobutyl carbinol (MIBC), terpineol, and ethyl glycol butyl ether (EGBE), to investigate their synergistic behaviors for oil separation. The interfacial phenomena were measured for a range of frother surface coverages on saltwater. Density profiles of the hydrophilic and hydrophobic portions of the frothers show an expected orientation of alcohol groups adsorbing to the polar water. A decrease in surface tension with increasing surface coverage of MIBC and terpineol was observed and reflected in experiments where the frother concentration increased. Relations between surface coverage and bulk concentration were observed by comparing the surface tension decreases. Additionally, a range of oil surface coverages was explored when the interface has a thin layer of adsorbed frother molecules. The obtained results indicate that an increase in surface coverage of oil molecules led to an increase in surface tension for all frother types and the pair correlation functions depicted MIBC and terpineol as having higher distributions with water at closer distances than with oil.

For water treatment purposes, the separation processes involving surfactants and crude oil at seawater-air interfaces are of importance for the chemical and energy industries. Little progress has been made in understanding the nanoscale phenomena of surfactants on oily saltwater-air interfaces. This work focuses on using molecular dynamics with a united-atom force field to simulate the interface of linear alkane oil, saltwater, and air with three surfactant frothers: methyl isobutyl carbinol (MIBC), terpineol, and ethyl glycol butyl ether. For each frother, although the calculated diffusivities and viscosities are lower than the expected experimental values, our results show that diffusivity trends between each frother agree with experiments but the method cannot be applied for viscosity. Binary combinations of liquid (frother or saltwater)-air and liquid-liquid interfaces are equilibrated to study the density profiles and interfacial tensions. The calculated surface tensions of the frother-air interfaces are like that of oil-air, but lower than that of saltwater-air. Only the MIBC-air and terpineol-air interfaces agreed with our experimental measurements. For the frother-saltwater interfaces, the calculated results showed that terpineol has interfacial tensions higher than those of MIBC-saltwater. The simulated results indicate that the frother-oil systems underwent mixing such that the density profiles depicted large interfacial thicknesses.

CO2 reduction to valuable products is a centerpiece of future energy and sustainability technologies, yet progress in developing efficient and selective catalysts has been limited by the challenges in measuring the performance of electrocatalysts, including sensitivity to the electrochemical environment and the breadth of possible reaction products. The ideal characterization of a given catalyst is quantitative measurement of the activity and product distribution, as a function of time and for a large range of overpotentials since product distributions vary with aging of the operational catalyst as well as the operating potential. This combination of desired measurement attributes is incompatible with traditional experiments, perhaps most notably due to the duration of quantitative product distribution measurements, which impedes measurements over a range of overpotentials and severely limits the measurement frequency to observe variations in product distribution. We present principled design of high throughput screening systems and discuss the implications that these designs have for large-scale reactors. We will also discuss initial results of the high throughput screening that reveal surprising compositional trends in product distributions and provide key examples of where understanding of the uniqueness of Cu in producing high-order products needs to be further developed.

We report a straightforward and transferrable synthesis strategy to encapsulate metal oxide nanoparticles (NPs) in mesoporous ZSM-5 via the encapsulation of NPs into silica followed by conversion of the NP@silica precursor to NP@ZSM-5. The systematic bottom-up approach allows for straightforward, precise control of both the metal weight loading and size of the embedded NP and yields uniform NP@ZSM-5 microspheres composed of stacked ZSM-5 nanorods with substantial mesoporosity. Key to the synthesis is the timed release of the embedded NPs during dissolution of the silica matrix in the hydrothermal conversion step, which finely balances the rate of NP release with the rate of SiO2 dissolution and the subsequent nucleation of aluminosilicate. The synthesis approach is demonstrated for Zn, Fe, and Ni oxide encapsulation in ZSM-5 but can be expected to be broadly transferrable for the encapsulation of metal and metal oxide nanoparticles into other zeolite structures.