Xiao
Ma‡
ab,
Gong
Zhang‡
ab,
Jie
Du
ab,
Xiaoyun
Lin
ab,
Shiyu
Zhen
ab,
Dongfang
Cheng
ab,
Chaoxi
Wang
ab,
Xin
Chang
ab,
Shican
Wu
ab,
Xiangcheng
Shi
abc,
Lyudmila
Moskaleva
d,
Peng
Zhang
abcefg,
Zhi-Jian
Zhao
*abefg and
Jinlong
Gong
*abeh
aSchool of Chemical Engineering & Technology, Key Laboratory for Green Chemical Technology of Ministry of Education, Tianjin University, Tianjin, 300072, China. E-mail: zjzhao@tju.edu.cn; jlgong@tju.edu.cn
bCollaborative Innovation Center for Chemical Science & Engineering (Tianjin), Tianjin, 300072, China
cJoint School of National University of Singapore and Tianjin University, International Campus of Tianjin University, Binhai New City, Fuzhou, 350207, Fujian, China
dDepartment of Chemistry, University of the Free State, P.O. Box 339, Bloemfontein 9301, South Africa
eInternational Joint Laboratory of Low-carbon Chemical Engineering, Tianjin 300350, China
fHaihe Laboratory of Sustainable Chemical Transformations, Tianjin 300192, China
gNational Industry-Education Platform of Energy Storage, Tianjin University, 135 Yaguan Road, Tianjin 300350, China
hTianjin Normal University, Tianjin 300387, China
First published on 16th May 2025
This paper describes a detailed simulation approach to simulate the redox process on CuZn alloys, bridging traditional calculations with large-scale, multi-step processes. Through comprehensive redox process simulation, we identify the specific active sites for ethanol production on redox-treated CuZn surfaces while establishing a universally applicable simulation method.
New conceptsThis paper describes an innovative strategy to bridge traditional DFT calculations with large-scale and multi-step processes. By innovatively dividing the redox process into surface oxidation/reduction and oxygen diffusion processes, we reduced the complexity of the dynamics simulation process. Unlike previous work, which could only simulate single reaction processes, this innovative multi-equilibrium step simulation approach enables us to simulate the whole redox process on CuZn alloy catalysts, making it possible to trace the surface structure evolution of CuZn alloys during redox treatment and enabling us to gain detailed insight into special active sites for ethanol production. After the redox process, we classified the active sites by energy and geometric structure, indicating that the redox treatment creates several classes of specific active sites on CuZn surfaces. These sites alter the strength of the C–O bond in the selectivity-determining intermediate (*OC2H3), which is critical for ethanol formation. Specifically, Cu-rich step sites enhance ethanol selectivity by preserving the C–O bond. This work provides new insights into the mechanism of activity changes on oxide-derived CuZn surfaces through long-term simulation, which could potentially guide the precise design of electrocatalysts for renewable energy applications. |
Cu-based bimetallic systems have shown great potential to enhance ethanol yield. For instance, CO spillover effects over CuAg, CuAu and CuZn30–33 alloys are believed to promote C2+ product formation by increasing local CO coverage. Additionally, Cu alloying with metals of different oxygen affinities directly impacts the C–O bond strength in SDI, thereby tuning the selectivity of C2+ products.34 Among guest metals like Ag, Au, and Zn, CuZn catalysts are particularly attractive due to their cost-efficiency and ability to finely tune C–C coupling energies to enhance C2+ products (near to 0.67 eV).35–37 Unfortunately, Zn atoms, with stronger oxygen affinity, may unfavorably affect C–O bond preservation and reduce ethanol production among C2+ products.21,35 Additional methods are necessary to balance Zn atom oxygenophilicity to preserve the C–O bond.
Geometric structure regulation represents a promising approach for ethanol production, as demonstrated by recent studies identifying specific active sites on reconstructed Cu catalysts that selectively produce C2+ productions, especially ethanol production. The specific activity of the OD–Cu catalysts has attracted significant attention since the groundbreaking work by Kanan and colleagues.38 For instance, Chorkendorff et al.39 demonstrated through temperature-programmed desorption that redox-treated Cu catalysts exhibit multiple CO binding sites with distinct adsorption energies. Subsequently, isotope labeling studies by Ager et al.40 established a direct correlation between these specific active sites and the formation of various C2+ products. These studies revealed that redox treatment of Cu surfaces could generate distinct active sites that promote the formation of C2+ products.
Further investigations have revealed that the enhanced C2+ selectivity can be attributed to specific low-coordination sites generated during this process. Goddard et al.41,42 demonstrated that active sites on twin boundaries of Cu catalysts reduce the reaction energies of C–C coupling steps and promote C2+ production. Notably, detailed DFT calculations have elucidated that certain surface structures, particularly 4AD@Cu(100)43 and step-square sites,20 exhibit preferential activity toward ethanol production. The special sites for ethanol production on monometallic catalysts inspired us to investigate similar active sites on alloy systems by implementing redox processes on CuZn alloys.
CuZn-based catalysts have already demonstrated excellent catalytic properties for CO2RR to ethanol. However, due to the unclear distribution and reconstruction of CuZn atoms, as well as the difficulty in characterizing specific surface structures on CuZn catalysts, researchers tend not to correlate ethanol production with active sites. Nevertheless, we hypothesize that there might be active sites similar to those on OD-Cu catalysts that promote ethanol production and that these sites may be one of the potential factors that have been overlooked.
Unfortunately, due to the similar atomic size of copper and zinc (Zn) and the insufficient spatial resolution of current in situ characterization techniques, detecting active sites for ethanol production on these catalysts remains challenging, hindering further development of CuZn catalysts. Although density functional theory (DFT) methods are widely employed for active site detection, quantum mechanics (QM) calculations are impractical for large-scale and long-term simulation on CuZn alloys. Moreover, the multistep and large-scale nature of the redox process complicates simulation of the reconstruction process on CuZn alloys, necessitating a strategy to simulate the dynamic reconstruction process on the catalyst.20,42,44,45
In this study, we employed a series of equilibrium steps to simulate the entire redox process, starting from the initial metallic CuZn alloy. The emergence of special active sites for ethanol during the redox process was verified. These sites demonstrate a collaborative effect between the geometric structure and the difference in the oxygen affinity of guest elements, altering the binding configuration of the selectivity-determining intermediate (*OC2H3) from a monodentate configuration to a bridge-like dual-bond configuration on Cu-rich step sites. This modification balances the negative effects caused by the oxygenophilicity of Zn atoms, strengthening the C–O bond and improving ethanol production. Based on these theoretical simulations and mechanistic insights, we employed a redox strategy to modify the surface configuration of CuZn alloys, achieving a high FE for ethanol under high current density (>40% at 300 mA cm−2). This study demonstrates a theoretical framework for designing highly selective Cu-based catalysts through the synergistic control of alloy effects and geometric structures. Additionally, the developed simulation approach offers a universal framework for redox processes on metal surfaces. Furthermore, the integration of machine learning-accelerated theoretical calculations with experimental validation provides theoretical guidance for the rational design of the Cu-based alloys.
:
Zn ratio close to 3
:
1 has the highest FE for C2+ products and ethanol (see details in Fig. S1, ESI†). Therefore, we used the metallic Cu3Zn (111) surface as the initial state to start the molecular dynamics simulation with a neural network potential (NN-MD).46,47 We divided the entire redox process into two main steps: oxidation under an oxygen atmosphere and the following reduction step under vacuum. The entire simulation workflow is shown in Fig. 1. To simulate the oxidation process of the CuZn alloy, we suggest that continuous oxidation contains two sequential sub steps: oxygen adsorption and diffusion. Considering that the oxidation process tends to occur at sites with higher oxygen binding energies,48 we first calculated the adsorption energy of oxygen atoms (E*O) on the initial CuZn surface using a neural network potential. We then sequentially added O atoms in order from highest to lowest E*O and calculated the chemical potential of the adsorbed oxygen after each addition. When the chemical potential of oxygen approaches zero, the oxygen adsorption is terminated (see details in Fig. S2–S5, ESI†). Next, we simulated the diffusion using the canonical ensemble (NVT) by performing neural network molecular dynamics (NN-MD) simulations on surfaces covered by oxygen. Similar to previous studies on Cu oxidation,49–52 we found that oxygen atoms prefer to adsorb around low coordinate sites and form oxides, then diffuse deeper through these oxides. By cycling between adsorption and diffusion processes, we successfully modelled the oxidation process of the CuZn alloy.
After obtaining a relatively stable CuZn alloy oxide, the simulation of the reduction process was initiated. This process, the reverse of oxidation, can be divided into sequential diffusion and removal sub-steps. First, canonical ensemble (NVT) kinetic simulations were employed to simulate oxygen migration and obtain a thermodynamically balanced structure. After the total energy of the system stabilizes, a relatively stable structure is obtained with oxygen accumulating near the surface. Subsequently, the oxygen removal process began.
In this process, we calculated the oxygen vacancy formation energy (Eov) for each oxygen atom on the surface (see the Methods section in the ESI,† for the detailed formula), which considers the electrochemical reduction of oxygen to water. While this approach differs from conventional defect formation energy calculations53 that typically yield positive values under thermodynamic equilibrium, our method specifically aims to identify the relative ease of oxygen reduction during the electrochemical process. We utilized the relative values of Eov to determine the sequence for removing oxygen atoms to simulate the reduction process. This process created a partially reduced surface. This was followed by another round of NVT simulation to allow the system to reach equilibrium, during which subsurface oxygen atoms diffused to the surface. Following this protocol,20,54,55 we developed a realistic surface model of OD-CuZn, in which oxygen atoms were either removed or trapped below the third layer, with the trapped oxygen shown to have minimal effect on the adsorption behaviors of adsorbates.54,56
For the OD-CuZn, obvious surface reconstruction is observed (see details in Fig. S6–S11, ESI†), generating a series of active sites with different Zn doping modes. To categorize these different sites, we used the binding energy of *CO and *OCCO intermediates (E*CO and E*OCCO) as descriptors to perform the high-throughput screening, given that they are key intermediates for C2+ products.17,57 Combining the cluster analysis results of E*CO and E*OCCO with geometric structure information (see details in Fig. S12–S15, ESI†), we classified the existing surface sites into four groups (Fig. 1). Sites on (111) facets doped with Zn atoms accounted for the majority (39%), while step-square sites doped with Zn occupied a similar percentage (38%). Lastly, planar-square and defect sites occupied relatively small proportions (16% and 7%, respectively). This suggests that the square sites (planar-square and step-square) are still the main sites for the generation of C2+ products. It seems that zinc doping does not affect the type of the main site for C2+ products.
Our analysis encompassed 316 zinc-doped active sites, comprising 109 step-square sites, 107 planar-square sites, and 100 sites on (111) faces. To ensure unbiased sampling, these sites were randomly selected from both existing and optimized structures (detailed methodology provided in the ESI†). We found that for planar-square and step-square zinc-doped sites, their average *CO dimerization energies are significantly lower than those of Zn doped (111) surfaces and lower than those of pure copper sites with the same geometrical configurations (Fig. 2b). This finding is consistent with our cluster analysis results.
The reaction pathway toward ethanol and ethylene formation has been extensively investigated, with the *OC2H3 hydrogenation pathway being identified as thermodynamically favorable for C2H4/C2H5OH production. This pathway has gained considerable support from experimental observations and theoretical calculations, including studies on Cu(100) surfaces19 and Cu vacancies,22 and *OC2H3 has been widely recognized as a key intermediate in several influential works.19,20,22,26,58 Although various intermediates have been proposed for CO2 electroreduction to C2+ products,59,60 *OC2H3 has emerged as a critical intermediate species owing to its favorable thermodynamic properties.19 Our theoretical calculations further supported this understanding (Fig. S16, ESI†). Using *OC2H3 as the key intermediate, we investigated how the C–O bond activation varies across different surface sites. The pathway to ethylene proceeds through hydrogenation followed by C–O bond cleavage, whereas ethanol formation occurs via direct protonation while maintaining the C–O bond. Using the difference between reaction energies of ethylene and ethanol (ErC2H4 − ErC2H5OH) as a descriptor, we constructed stacked histograms (Fig. 2c). We found that the step-square sites exhibited the largest energy difference compared to all other sites. Indicating that these sites could be the major source of high ethanol selectivity observed on the OD-CuZn surface.
To explain the molecular mechanism for high ethanol selectivity at these sites, we analyzed the C–O bond lengths of the *OC2H3 intermediate20–22 on over 2000 active sites. We found that the C–O bond lengths primarily clustered into three major groups (Fig. 3a). The corresponding average bond lengths of these three groups are 1.36–1.38 Å, 1.31–1.33 Å, and 1.27–1.29 Å, respectively. Sites on doped (111) faces had the longest average bond length (1.36–1.38 Å), corresponding with the lowest ethanol selectivity, while the shorter bond lengths on zinc-doped planar-square (1.31–1.33 Å) likely corresponded to higher ethanol selectivity.
Interestingly, bond lengths on step-square sites were categorized into two subgroups: Cu-rich step sites (with more Cu atoms concentrated at the edge of the step) and Zn-rich step sites (with more Zn atoms concentrated at the edge of the step). Zn-rich step sites had an average C–O bond length of 1.31–1.33 Å, similar to that of zinc-doped planar-square sites, while Cu-rich step sites had an average length of 1.27–1.29 Å, shorter than other sites. This difference arises from the distinct adsorption configurations of the *OC2H3 intermediate (Fig. 3b). We found that on these sites, the adsorption configurations of the *OC2H3 intermediate differ, which might contribute to the difference in bond length and energy. For Zn-rich step sites, the *OC2H3 intermediate tends to adsorb on the edge of the step sites in a monodentate configuration. In contrast, on Cu-rich step sites, it tends to adsorb on the terrace sites away from step sites in a bridge-like dual-bond configuration. To further explore the impact of adsorb configuration on selectivity, we calculated the free energy of the ethylene and ethanol formation (Fig. 3c and d). We found the difference of the free energy between ethylene and ethanol pathways is larger for the bridge-like dual-bond configuration, indicating a higher ethanol selectivity compared to the monodentate configuration. Moreover, we calculated the charge density difference and COHP in these adsorption configurations (Fig. S17, ESI†) and found that on the Zn-rich step sites, blue clouds appear on the C–O bond in the *OC2H3 intermediates, which indicates decreased charge density in the C–O bond, suggesting lower bond strength compared to the *OC2H3 intermediates on Cu-rich step sites. Additionally, the C–O bond antibonding orbitals on Cu-rich step sites show lower occupation below the Fermi level (EF), indicating relatively stronger C–O bond strength at this site.
To gain a more detailed understanding of the kinetics, we additionally calculated the transition states to determine the C–O bond dissociation barriers.61 The results were consistent with the thermodynamic trends (Fig. 3e), showing that the energy barrier on Cu-rich step sites is significantly higher than that on other sites. This suggests that these special active sites can stabilize the C–O bond in *OC2H3 intermediates by changing the adsorption configurations, which may increase ethanol selectivity.
We tested the CO2 reduction performance of these samples. As expected, we observed higher partial current densities and FE for both C2+ products and ethanol compared to pure OD-Cu catalysts (Fig. S24, ESI†). This indicates that there may be more effective active sites for ethanol production on the OD-CuZn catalyst than on the OD-Cu catalyst. These active sites likely correspond to the theoretically predicted configurations: Zn doped step square sites, Zn doped (111) facets, Zn doped planar square sites, and Zn doped defect sites. Subsequently we annealed these OD-CuZn samples. The annealing treatment reduced the number of sites available in the OD-CuZn catalysts and correspondingly reduced the number of sites we predicted, resulting in a decrease in the formation of the C2+ product from about 60% to about 30% and a decrease in the ethanol/ethylene ratio from 1.5 to 1.0.
To probe the surface site structures before and after annealing, we only focused on using CO as a probe molecule in in situ Raman spectroscopy. The CO vibrational features were monitored as they were highly sensitive to the local coordination environment of surface adsorption sites.62–65 We observed that the CO peak on the untreated OD-CuZn was significantly broader than that on the annealed surface (Fig. 4a and b). Given that CO binding energies vary among different surface sites, the narrowing of the CO peak suggests a reduction in the diversity of surface sites after annealing. While C2+ intermediates were not detected here due to temporal resolution limits, future time-resolved spectroscopic studies may provide complementary insights, though this lies outside our current focus on surface evolution. We also characterized the catalysts using transmission electron microscopy (TEM). After annealing, the lattice fringes showed a more uniform orientation (see details in Fig. S25 and S26, ESI†). This morphological evolution could lead to a decrease in the number of specific active sites. This observation is consistent with previous work demonstrating surface restructuring after thermal treatment,20,39 and it aligns with the observed decrease in ethanol selectivity (Fig. 4c and d).
In our future work, we intend to employ advanced characterization techniques, including in situ electrochemical cryo-electron microscopy or in situ electrochemical scanning tunnelling microscope with enhanced spatial resolution. These techniques will help overcome the current limitations in investigating site geometry, which will enable closer integration of experimental and theoretical calculations. Furthermore, we plan to establish more comprehensive scaling relationships to guide the rational design of catalysts. These efforts will advance our fundamental understanding of CO2 electroreduction catalysis and accelerate the development of high-performance catalysts.
Footnotes |
| † Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d5mh00417a |
| ‡ X. M. and G. Z. contributed equally. |
| This journal is © The Royal Society of Chemistry 2025 |