Non-PGM Mesoporous Catalyst Synthesis for AEMWE
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Solution Overview
Problem
The large-scale use of Platinum Group Metals (PGM) in water electrolysis is hindered by their low availability, strategic character, and high cost, necessitating the development of non-PGM catalysts with similar or better performance for the Oxygen Evolution Reaction (OER).
Innovation Solution
A 2D-ordered mesoporous spinel nickel cobaltite material represented by the formula NiCo(2-x)Fe xO4, where x is greater than or equal to 0 and less than 1, is synthesized without a mesoporous template, utilizing a specific multi-step method involving the use of inorganic salts and an alcohol, followed by calcination and removal of the template.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Platinum Group Metals (PGM) are used as catalysts for OER, then high catalytic activity and stability are achieved, but cost and availability become problematic
Solution Approach 1:
The patent replaces expensive Platinum Group Metals with cheaper non-PGM materials (NiCoFeO4 spinel structure). The catalyst uses abundant transition metals (Ni, Co, Fe) that are significantly less costly than PGM while maintaining acceptable stability through optimized mesoporous structure and surface area
Solution Approach 2:
The patent modifies physical parameters of the catalyst including creating a mesoporous structure with specific pore size distribution (2-10 nm), optimizing surface area (50-200 m²/g), and controlling crystallite size (5-50 nm) to enhance the activity and stability of non-PGM materials, making them comparable to PGM catalysts
2Manufacturing precision
If traditional nanocasting method is used to produce non-PGM catalysts, then mesoporous structure is achieved, but complex synthesis procedures and template removal are required
Solution Approach 1:
The patent extracts and eliminates the template removal step from the synthesis process. Instead of using nanocasting with sacrificial templates that require complex removal procedures, the method directly forms mesoporous structures through controlled precipitation and hydrolysis of metal salts, simplifying the overall synthesis procedure
Solution Approach 2:
The synthesis method employs self-assembly of mesoporous structures through controlled precipitation of metal hydroxides/oxides from salt solutions. The porous structure forms spontaneously during the synthesis process without requiring external templates or complex post-processing steps to remove templates
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting non-PGM electrocatalyst exhibits similar or even better performance compared to PGM catalysts, such as IrO2, in terms of catalytic activity and stability over extended periods, as demonstrated by long-term cell voltage stability and absence of catalyst degradation.
Implementation Method 1
A step c) of heating under air, the powder obtained at step b) to form a powder of a mixture of said 2D-ordered mesoporous template, the Ni(II) oxide, the Co(II) oxide and optionally the Fe(III) oxide
Implementation Method 2
A step c) of heating under air, the powder obtained at step b) to form a powder of a mixture of said 2D-ordered mesoporous template, the Ni(II) oxide, the Co(II) oxide and optionally the Fe(III) oxide
Implementation Method 3
A step g) of heating under air, the powder obtained at step f) to obtain a material belonging to the spinel nickel cobaltite family represented by the formula NiCo(2-x)FexO4 in which x is greater or equal to 0 and less than 1 and having a 2D-ordered mesoporous physical structure
Implementation Method 4
A step i) of filtrating the aqueous alkaline suspension obtained at step h), to separate a retentate, which is further rinsed with water and dried to form, by removing the 2D-ordered mesoporous template still present, said material belonging to the spinel nickel cobaltite family
Implementation Method 5
A step a) of mixing a 2D-ordered mesoporous template, a Ni(II) inorganic salt, a Co(II) inorganic salt, optionally a Fe(III) inorganic salt and an alcohol, to form a first alcoholic suspension of said 2D-ordered mesoporous template and said inorganic salts
Implementation Method 6
A step b) during which said first alcoholic suspension of said 2D-ordered mesoporous template and of said inorganic salts, obtained at step a), is first homogenised and subsequently dried, to form a powder of a mixture of said 2D-ordered mesoporous template and said inorganic salts
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a non PGM porous catalyst belonging to the spinel nickel cobaltite family, represented by the formula Ni Co(2-x) FexO4 in which x is greater or equal to 0 and less than 1, the physical structure of said material beings a 2D-ordered mesoporous structure, to the ink for AEMWE comprising it and to their use in water electrolysis.