Xiang
Ji
,
Yaodong
Yu
,
Yujia
Guan
,
Jianping
Lai
* and
Lei
Wang
*
State Key Laboratory Base of Eco-Chemical Engineering, Ministry of Education, International Science and Technology Cooperation Base of Eco-Chemical Engineering and Green Manufacturing, College of Chemistry and Molecular Engineering, Qingdao University of Science and Technology, Qingdao 266042, P. R. China. E-mail: jplai@qust.edu.cn; inorchemwl@126.com
First published on 26th September 2025
Traditional neutral/alkaline systems face limitations due to incompatibility with acidic industrial wastewater and spontaneous carbonate byproduct formation, causing reactant depletion and low efficiency. While acidic conditions enhance industrial applicability, challenges persist: insufficient adsorption energy for key intermediates, hydrogen evolution reaction (HER) competition, and catalyst corrosion. This study developed a porous core–shell CuAu@Cu2O catalyst, achieving 55.4% faradaic efficiency and 1824.8 μg h−1 mg−1 urea yield at −0.5 V vs. RHE in acidic media, with 100-hour stability. Mechanistic insights reveal that Cu/Au dual sites synergistically activate CO2 and NO3−, lowering *COOH/*NOH intermediate adsorption energies; the Cu2O shell regulates proton supply via Au-mediated electronic effects, promoting C–N coupling while suppressing the HER; and charge redistribution from Cu to Au at the porous interface stabilizes the catalyst structure. This work not only provides an efficient catalyst for urea electrosynthesis under acidic conditions, but also pioneers a novel ‘waste-treating-waste’ green synthesis paradigm, offering new insights for electrochemical manufacturing in the context of carbon neutrality goals.
Green foundation1. We pioneer acid-tolerant electrocatalytic urea synthesis by coupling CO2 valorization with acidic nitrate wastewater treatment. This approach overcomes the limitations of carbonate precipitation, reactant loss and wastewater incompatibility and bypasses the Haber–Bosch process.2. CuAu@Cu2O enables the direct conversion of acidic nitrate wastewater and CO2 into urea without the need for pH adjustment, while maintaining operational stability for 100 hours under mild potentials. 3. For more sustainable development, future efforts could focus on replacing the oxygen evolution reaction with value-added anodic oxidations and scaling up the process using flow cells or membrane assembly devices to further reduce energy consumption. |
The complexity of electrocatalytic urea synthesis arises from its multi-step mechanism involving CO2 reduction to *CO (via *COOH intermediates), nitrate reduction to *NH2 (via *NOH pathways), and subsequent C–N coupling – all requiring precise regulation of 16-electron transfer processes.19–22 Recent advances highlight multi-active-site engineering as an effective strategy to optimize distinct reaction steps.1,23,24 Core–shell structures like Au@Cu2O can create a charge barrier to mitigate acidic corrosion.11 Considering the abovementioned points, the design of core–shell catalysts with multiple active sites is anticipated to resolve the intertwined challenges of activity, selectivity, and stability in acidic C–N coupling systems. Here, we designed a porous CuAu@Cu2O core–shell catalyst that achieves 55.4% faradaic efficiency and 1824.8 μg h−1 mg−1 urea yield in weakly acidic media (pH = 3, −0.5 V vs. RHE). Au and Cu components respectively reduce the adsorption energies of *COOH and *NOH intermediates, thereby generating *CO and *NH2, while Cu2O phases modulate the hydrogen adsorption strength to balance proton supply and HER suppression. Charge redistribution from Cu to Au at their interface, driven by electron transfer, achieves dual catalytic enhancements: it stabilizes Cu+ species to suppress disproportionation while simultaneously optimizing interfacial activity through d-band center modulation of Au. Specifically, the downward-shifted d-band center strengthens CO2 adsorption/activation, whereas precisely tuned hydrogen adsorption energy barriers steer the reaction pathway toward favorable CO2 hydrogenation over the competing hydrogen evolution reaction (HER). This synergistic mechanism achieves dual modulation of catalytic selectivity at the electronic structure level. This breakthrough establishes the first efficient acidic electrocatalytic system for direct CO2–nitrate coupling while demonstrating a material design paradigm that integrates intermediate optimization, HER suppression, and structural stabilization. The work provides fundamental principles for multi-active-site catalyst engineering and practical strategies for valorizing acidic wastewater in sustainable urea synthesis.
The XRD patterns of CuAu@Cu2O (Fig. 2a and S5) exhibit dominant diffraction features corresponding to Cu(111) and Cu2O(111). Notably, the Cu(111) peak displays a negative shift compared to that of Cu@Cu2O, indicating an expanded d-spacing. This lattice expansion arises from the incorporation of Au atoms into the Cu lattice to form a CuAu alloy, as supported by HRTEM analysis.28 The persistent Cu2O(111) peak confirms the retention of a Cu2O phase in the outer shell, collectively demonstrating the successful construction of a core–shell architecture. XPS analysis further clarifies the electronic states of the constituent elements. The Au 4f7/2 peak at 84.2 eV corresponds to metallic Au(0) (Fig. 2b), confirming the non-oxidized state of Au within the alloyed core. The Cu 2p3/2 peak at 932.7 eV aligns closely with the characteristic binding energy of Cu+ in Cu2O (933.0 eV) (Fig. 2c), suggesting the coexistence of Cu+ and Cu(0) species in the shell.29,30 This conclusion is further reinforced by the Cu Auger LMM peak at 572.3 eV (Fig. 2d), providing complementary evidence for the stable presence of both +1 and 0 oxidation states of copper.10,31
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| Fig. 2 Structure of CuAu@Cu2O. (a) XRD of CuAu/Cu2O. (b) Au 4f, (c) Cu 2p, and (d) Cu LMM XPS spectra of CuAu/Cu2O. | ||
The electronic structure of CuAu@Cu2O was investigated using UPS and UV-Vis diffuse reflectance spectroscopy. These analyses reveal that the synergistic modulation of the direct bandgap (∼2.68 eV) and valence band maximum (VBM, ∼1.83 eV) (Fig. S6) in CuAu@Cu2O enables precise alignment of its conduction band minimum (CBM, ∼−0.85 eV) (Fig. S7) with the thermodynamic potential window (−0.4 V vs. RHE) required for NO3− reduction (to NH2) and CO2 activation.32–34 The superior reduction potential of nitrate suppresses the HER, directing adsorbed *H species to preferentially participate in C–N coupling.34 Concurrently, the electronic interaction between Au and Cu2O induces a significant reduction in work function (ΔΦ = 0.42 eV, Fig. S8), shifting the Fermi level toward the valence band.35 This interfacial charge redistribution generates a surface dipole, which, combined with the plasmonic coupling effect of Au, further weakens the H+ adsorption energy barrier (ΔG_H → 0), steering *H toward urea synthesis rather than the HER.36
The core–shell architecture drives interfacial electron transfer through the work function difference between Au and Cu, resulting in electron enrichment at Au and depletion at Cu+. This not only suppresses the Cu+ disproportionation reaction (2Cu+ → Cu2+ + Cu0), but also optimizes intermediate adsorption energies through the CuAu alloy core, synergizing with the selective inhibition effect of the Cu2O shell to endow the material with high catalytic activity and stability. Such electronic structure optimization enhances the charge transfer efficiency while suppressing competitive side reactions (HER) and reducing kinetic barriers in key steps, significantly improving both selectivity and catalytic activity for urea synthesis. This establishes an efficient electron-energy cooperative regulation mechanism for multi-proton-coupled C–N coupling reactions.
Competing side reactions (e.g., NO3−RR, CO2RR, and HER) suppress the co-reduction of CO2 and NO3− to urea, resulting in a complex product distribution (Fig. S17), including urea, ammonia, nitrite, H2, and CO, with a near 100% total faradaic efficiency. The urea faradaic efficiency follows a volcano-shaped dependence on the applied potential (Fig. 3a and b), peaking at 55.4% for CuAu@Cu2O at −0.5 V vs. RHE, corresponding to a production rate of 1824.8 μg h−1 mg−1, outperforming most reported electrocatalysts (Table S2).38
To identify active sites for specific reactions, individual CO2RR, NO3−RR, and HER tests were conducted. Au@Cu2O achieves a CO faradaic efficiency (FE) of 82.14% for CO2RR but only 12.63% FE for NH3 generation at −0.4 V vs. RHE (Fig. S18). Conversely, Cu@Cu2O delivers a high FE of 66.21% for ammonia electrosynthesis, yet a low CO FE of 5.63% at −0.4 V vs. RHE (Fig. S19), confirming that Cu and Au sites preferentially adsorb nitrate and CO2, respectively. Additionally, HER activity of the core–shell catalyst is significantly lower than that of the CuAu alloy (Fig. S20), attributed to the strong *H adsorption capability of Cu sites in CuAu. We also compared the HER polarization curves of CuAu and CuAu@Cu2O in a 1 M KCl electrolyte (pH = 3). The HER activity of CuAu@Cu2O was significantly suppressed, highlighting the role of the Cu2O shell in optimizing *H adsorption and promoting proton utilization for C–N coupling (Fig. S21). However, CuAu@Cu2O retains moderate *H adsorption capacity. The HER competes with the CO2RR and NO3−RR in standalone reactions, explaining the mediocre performance of the CuAu alloy compared to CuAu@Cu2O.
Remarkably, CuAu@Cu2O shows drastically reduced CO, NH3, and H2 yields but a sharp increase in urea production compared to other samples. This is ascribed to its balanced adsorption strengths for *CO, *NH2, and *H, facilitating the coupling of *CO and *NH2 intermediates to form *CONH2, consistent with the Sabatier principle. Electrochemical impedance spectroscopy (EIS) confirms the high charge transfer efficiency of CuAu@Cu2O (Fig. S22), attributed to its abundant active sites and optimized electronic structure, which synergistically promote balanced activation of NO3− and CO2 for efficient C–N coupling.
To verify the nitrogen source in the electrochemically synthesized urea, isotope labeling experiments were performed. The electrocatalytic reaction was conducted at −0.5 V vs. RHE in an electrolyte containing 98% atom 15N-labeled K15NO3 (Sigma-Aldrich). Subsequent analysis by 1H NMR spectroscopy (Fig. 3c) revealed signals exclusively corresponding to 15N-labeled urea and 15N-labeled ammonia. The absence of signals from non-labeled nitrogen species and the sole presence of 15N-labeled urea confirm that the nitrate ions (15NO3−) in the electrolyte served as the primary nitrogen source for the urea produced in this system. Furthermore, experiments to verify the carbon source revealed that using an Ar-saturated electrolyte containing 0.2 M K2CO3 and 0.1 M KNO3 yielded only trace amounts of urea (FE < 2%), whereas continuous CO2 bubbling in an identical electrolyte significantly enhanced urea production, achieving a rate of 1824.8 μg h−1 mg−1. This stark contrast demonstrates that gaseous CO2, not carbonate ions (CO32−), serves as the essential carbon source for urea formation, confirming successful urea synthesis from nitrate (NO3−) and CO2 (Fig. 3d).
The stability of the catalyst during electrochemical processes was rigorously evaluated. The morphology and crystalline structure of the CuAu@Cu2O catalyst during electrochemical urea synthesis were investigated through TEM, XPS, and XRD characterization methods before and after electrolysis. As shown in Fig. S23, SEM and TEM images of CuAu@Cu2O after C–N coupling at −0.5 V vs. RHE show negligible morphological changes, indicating no significant particle aggregation. Furthermore, XRD patterns after electrolysis confirm that CuAu@Cu2O retains its crystalline structure (Fig. S24a), demonstrating high stability under operational conditions. Post-electrolysis XPS analysis reveals no notable changes in surface chemical states (Fig. S23b–d), while the ICP-OES results (Tables S1 and S3) before and after electrolysis confirm that the catalyst's composition remains largely unchanged, validating the structural integrity of the core–shell architecture. A 100-hour durability test at −0.5 V vs. RHE (Fig. S25 and Fig. 3e), with periodic electrolyte replenishment every 10 hours, confirms the commendable stability of CuAu@Cu2O throughout the prolonged experiment.
To test the catalytic performance over a wider pH range, we conducted additional experiments at pH = 1, 2, 3, 4, and 5 (Fig. S26). The results demonstrate that the catalyst shows optimal urea faradaic efficiency (55.4%) at pH = 3. Under stronger acidic conditions (pH = 1, 2), the urea faradaic efficiency decreases to approximately 35.68% and 42.37%, primarily due to intensified hydrogen evolution reaction (HER) competition caused by excessive protons. At pH = 4 and 5, the selectivity also declines (FE ∼ 44.83% and 40.05%), likely owing to insufficient proton supply affecting the C–N coupling step. The choice of pH = 3 represents an optimal balance among multiple factors: it provides adequate protons to promote C–N coupling, avoids severe HER competition induced by excessive protonation, maintains the structural stability of the Cu2O shell (which may partially dissolve under stronger acidic conditions), and aligns with the typical pH range of actual acidic industrial wastewater.
Between −0.4 and −0.6 V vs. RHE, vibrational signals from the *COOH intermediate (1046 cm−1, CO2 reduction) appear alongside δ(CN) (598 cm−1) and ν(CN) (1388 cm−1) vibrations, complemented by a ν(C
O) peak at 1719 cm−1, collectively corroborating urea formation.40 These results align with the hypothesis that *CONH2 formation is the critical step in urea synthesis. Additional in situ Raman tests on different catalysts (Fig. 3f) reveal that *NH2 stretching vibrations occur only in Au-containing catalysts, while ν(C
O) vibrations appear exclusively in Cu-containing catalysts. This suggests that Au and Cu sites act as active centers for adsorbing *CO and *NH2 intermediates, respectively, consistent with the experimental findings.
DFT calculations on CuAu@Cu2O, CuAu, Au@Cu2O, and Cu@Cu2O models revealed mechanistic insights into urea synthesis. The adsorption configurations of the reaction intermediates on CuAu@Cu2O, CuAu, Cu@Cu2O and Au@Cu2O are shown in Fig. S28–32. For CO2 activation, CuAu@Cu2O exhibited a lower free energy barrier (1.418 eV) for the *COOH formation step compared to Cu@Cu2O (1.638 eV), highlighting Au's role in facilitating CO2 reduction (Fig. 4a). In nitrate reduction, Cu sites dominated the PCET-driven *NH2 formation, with the *NO → *NOH step requiring 0.60 eV on CuAu@Cu2O versus 0.52 eV on Au@Cu2O, aligning with experimental observations of high NO2−/NH3 selectivity. The *H adsorption energy on CuAu@Cu2O (0.369 eV) was lower than that on CuAu (0.438 eV), demonstrating Cu2O's capacity to supply protons for C–N coupling while suppressing the HER, as confirmed by the near-zero *H free energy on bare CuAu favoring hydrogen evolution (Fig. 4b).
Critical to urea formation, the *CONH2 coupling barrier was minimized at CuAu@Cu2O (−0.454 eV), significantly lower than Cu@Cu2O (0.641 eV), Au@Cu2O (−0.393 eV), and CuAu (−0.387 eV), underscoring synergistic effects among Cu (NO3− activation), Au (CO2 activation), and Cu2O (*H regulation) (Fig. 4c and d). The negative energy barrier for *CONH2 formation (−0.454 eV) indicates an exothermic process that is highly spontaneous thermodynamically. This value, relative to the separated *CO and *NH2 intermediates, reflects the stabilization energy (∼0.45 eV) generated by orbital overlap during the coupling process, which is consistent with our experimental observation of high reaction rates even at low temperatures. The further hydrogenation of *CO to form *CHO and the direct dissociation of the *NOH intermediate to form *N are both highly endergonic (with an increase in free energy). In contrast, the coupling of *CO and *NH2 to form *CONH2 exhibits a significantly negative change in free energy (ΔG = −0.454 eV), indicating that this step is spontaneous and rapid on the catalyst surface. This demonstrates that the catalyst can selectively suppress other highly competitive reduction pathways (e.g., NO3− → NH4+, CO2 → CH4) and direct the flow of electrons and protons toward the carbon–nitrogen coupling step to produce urea. These results collectively rationalize the catalyst's high urea selectivity and stability, with theoretical and experimental data converging on the essential roles of component synergy in intermediate optimization and HER suppression.
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