Ming
Miao
,
Haotian
Duan
,
Jiayao
Luo
and
Xin
Wang
*
College of Chemistry, Zhengzhou University, Zhengzhou 450001, P. R. China. E-mail: wangxin0620@zzu.edu.cn
First published on 28th July 2022
In recent years, electrocatalytic reduction of CO2 has been a focus in the research field. There are also various methods for synthesizing catalysts, such as the hydrothermal method, the arc method, electrospinning, etc. Here, we introduce the electrochemical deposition method. Compared with ordinary synthesis methods, electrodeposition has the advantages of simple processing, controllable conditions, high safety, and environmental friendliness. It is also a promising method for industrialized catalyst synthesis. In this review, we give a detailed introduction to electrodeposition, summarize the research progress of electrodeposition in the synthesis of catalysts, and discuss the key conditions in the preparation process, which are provided as a reference to synthesize next-generation electrodeposited electrocatalysts.
In order to improve the conversion efficiency of catalysts, the synthesis method plays a crucial role in controlling the structure and performance of electrocatalysts. Recently, various methods for synthesizing catalysts have also been developed by researchers, such as the hydrothermal method,14 the impregnation method,15etc. Although the catalysts synthesized by these synthetic methods have the advantages of large specific surface area and less agglomeration, there are also many limitations. These synthetic methods often require harsh environments, additional surfactants or capping agents, and high temperature conditions. The morphology and microstructure of nanomaterials cannot be easily and finely controlled. Moreover, the generated waste is highly toxic, and the mixture of pollutants and catalysts affects their long-term catalytic activity. In this context, electrodeposition is a promising alternative method for catalyst preparation. Electrodeposition has the following advantages: (1) fine control of electrodeposition can yield catalysts strongly bonded to the substrate with good homogeneity. For example, electrodes, current density, voltage, electrolyte composition, etc. can be easily regulated. (2) Morphologically controlled nanostructures can be prepared. (3) The deposition conditions are convenient and the operation is simple. However, electrodeposition also presents significant challenges, namely, the large experimental parameter space and the influence of the substrate on the morphology and chemical composition of the catalyst.
In this review, we introduce the recent progress of electrodeposition in the synthesis of catalysts in the CDRRs. Fig. 1 shows the main topics of this review. Various electrodeposition methods, including potentiostatic deposition, galvanostatic deposition and co-deposition, are discussed. And their advantages and challenges in CDRR applications are also discussed. In addition, we also discussed the influence of experimental parameters on the synthesis of the catalyst, including the deposition time, pH, additives and other factors. Finally, the research, challenges and future prospects of electrodeposition methods in the CDRRs are described.
Fig. 2 (a) Schematic diagram of the two-electrode system for constant current deposition of bismuth electrodes. Reproduced with permission.22 Copyright 2021, Elsevier. (b) Schematic diagram of electrocatalytic reduction of carbon dioxide in a three-electrode system and a summary of its performance. Reproduced with permission.23 Copyright 2016, Elsevier. |
In galvanostatic deposition, time and current are the two most important variables. Wang et al. deposited Sn on copper foil by controlling for a change in current density over the same deposition time (Fig. 2b).23 The catalyst was deposited at current densities of 5, 10, 15 and 20 mA cm−2 at a controlled deposition time of 10 min. At a current density of 5 mA cm−2, the small current density is not enough to deposit enough Sn to cover the matrix. For current densities of 10 and 15 mA cm−2, this system is suitable to create fine and compact particles. As for the current density of 20 mA cm−2, due to the serious hydrogen evolution reaction, the structure of the prepared catalyst is relatively loose and forms a columnar shape. It can be seen that the electrodeposition parameters can significantly control the morphology of the catalyst, resulting in the formation of dendritic, granular, columnar and other morphologies.
In the three-electrode system, the potential can be better controlled to adjust the morphology, surface structure and other properties of the catalyst, so as to obtain the most ideal catalyst. He et al. reported the synthesis of CuxAuy NWAs (nanowire arrays) in different proportions (i.e., CuAu, Cu3Au, and CuAu3) by the potentiostatic pulse electrodeposition method.25 The optimized CuxAuy NWAs showed high ethanol selectivity, with the FE of ethanol up to 45% at −0.7 VRHE. They controlled the atomic ratio by electrodeposition potential and further regulated the surface electronic structure of the catalyst. They found that during the CDRR process, due to the dense nanoarrays, the diffusion of OH− and *CO was restricted, resulting in higher local pH and *CO concentration on the nanowire surface, thus facilitating ethanol production.
The morphology and catalytic performance of the materials prepared using different electrodeposition methods are also divergent. Zhao et al. prepared hexagonal Bi sheets on copper foil by electrodeposition.26 The Bi film was deposited on a Cu substrate by the potentiostatic method, direct current electrodeposition method and pulse electrodeposition method, respectively. When the total charge passed is 20C, the deposition terminates. As shown in Fig. 3b, they prepared hexagonal, cubic and dendritic catalysts by different electrodeposition methods, respectively. The study showed that Bi slices prepared at a constant potential contained a large number of sharp edges and corners, which could improve the local electric field intensity and promote the rapid transfer of electrons. When the overpotential is −0.65 V, the FE of formate is close to 100%, and the yield is 96.37 μmol h−1 cm−2.
Fig. 3 (a) Scanning electron microscopy (SEM) images of catalysts prepared under different conditions before and after the CDRR reaction. Reproduced with permission.24 Copyright 2019, American Chemical Society. (b) SEM images of copper and deposits of Bi obtained by different electrodeposition methods: constant potential, CP; direct current, DC; and pulse current, PC. Reproduced with permission.26 Copyright 2021, Elsevier. |
Fig. 4 (a) Ag–Zn alloy growth and characterization. Reproduced with permission.27 Copyright 2020, Elsevier Inc. (b) Schematic diagram of SnCu alloy preparation and catalytic performance. Reproduced with permission.28 Copyright 2020, Elsevier. |
Fig. 5 Current curves and the corresponding SEM images of direct electrodeposition and pulse electrodeposition. Reproduced with permission.29 Copyright 2017, Elsevier. |
Pulse electrodeposition can yield catalysts with special structures by controlling the parameters. For example, Yu et al. designed a Cu–Pd heterostructure,30 and they synthesized the CuCl–PdOx precursor by double-potential pulsed electrodeposition. The treated electrode was reduced at −1.6 V (vs. Ag/AgCl) for 100 s to obtain Cu–Pd heterojunction. The catalyst has a unique selectivity for CH4 with an FE of 32%. Furthermore, Zhang et al. provided a new strategy for the preparation of highly (111) textured nanotwinned copper (nt-Cu) by medium-frequency pulse electrodeposition.31 The effect of Cu2+ concentration on the structure was discussed in detail. A simple and robust method for the future large-scale preparation of (111) nt-Cu is also proposed.
Non-self-supported catalysts usually exist in the powder form and are supported on the carrier by a binder. Inevitably, the use of a binder reduces the conductivity of the electrode, and prolonged catalysis also strips the bonded catalyst from the carrier. Yao et al. first reported the preparation of mesoporous Ni0.8Fe0.2 films by hydrothermal deposition as an OER catalyst.34 They show that hydrothermal deposition accelerates H2 overflow due to high temperature, and high pressure and rapid gas overflow facilitate the formation of more active sites compared to conventional electrodeposition methods.
The catalyst and matrix prepared by this method have a stronger binding force. Although hydrothermal deposition and droplet mediated electrodeposition are a little more complicated than traditional electrodeposition methods, they also have many references for the synthesis of catalysts. It is believed that the application of these methods to CDRRs will have a good prospect.
In this section, we introduce different electrodeposition methods. The main controllable parameter of chronopotentiometry electrodeposition is current density, which is simple to analyze and easy to deposit alloys. However, the electrode potential is easily fluctuated by external influences, and it is difficult to accurately control the current density. Therefore, it is more suitable for the three-electrode system. Due to the different reduction potentials of different metal ions, the chronoamperometry method is more suitable for the deposition of single metal or multi-layer metal. Pulse electrodeposition has three independent parameters, and the ion concentration on the electrode surface is more stable during the deposition process, so the phenomenon of concentration polarization becomes weaker. The resulting grains are smaller and the deposition is more uniform and denser. Electrodeposition also has its limitations. First, the controllable parameters of electrodeposition have a wide range of adjustment with many influencing factors, such as the deposition method, potential, current density, pH, additives, and electrolyte. Second, the lack of effective theoretical models to describe the relationship between parameters and properties of different systems limits the large-scale application of electrodeposition. Therefore, building a complete database and corresponding theories should be the direction of future development.
Overpotential has a substantial influence on the morphology of deposition.39 For example, Branco et al. studied the catalytic activity of copper with different morphologies and the effects of cathode potential.36 They deposited predominantly dendritic deposits in the plateau region of the limiting diffusion current density. As shown in Fig. 6a, the strength of dendritic growth was dependent on the applied potential. In the region within the current density plateau, copper dendrites are strengthened as the deposition potential increases. In the region beyond the current density plateau, due to the further evolution of HER, the length and number of dendrites will gradually decrease when the potential is increased. Interestingly, copper catalysts with honeycomb and foam-like structures can produce C2 products, suppressing the production of methane. This may provide a direction for electrochemical CO2 conversion applications.
Fig. 6 (a) SEM images of copper electrodes prepared by electrodeposition at different potentials. Reproduced with permission.36 Copyright 2013, Elsevier. (b) SEM images of Cu electrodeposited (I) without additive, (II) with DAT, (III) with dodecyltrimethylammonium bromide (DTAB), and (IV) with thonzonium bromide (ThonB). Reproduced with permission.37 Copyright 2017, American Chemical Society. (c) (I) Preparation of Cu electrocatalysts via electrochemical deposition followed by evaluation of catalytic performance. (II) Schematic illustration of machine-learning-guided optimization of additives for copper catalyst preparation. Reproduced with permission.43 Copyright 2021, American Chemical Society. |
In addition, the effect of electrolyte concentration on the deposition morphology is studied in Branco's work.36 They obtained the honeycomb-like structure by changing the concentration of H2SO4 to promote the attachment of hydrogen bubbles. With the increase of CuSO4 concentration, the reduction of copper ions is stronger than that of the HER, and the pore size and wall thickness are enhanced. This structure is beneficial to the rapid transport of gas and liquid, and the higher specific surface area is beneficial to CDRRs. The results show that the methane current efficiency decreases and the ethylene selectivity is enhanced for the catalyst deposited at higher overpotentials.
In the electrodeposition process, additives are often added into the bath to control the fine transform of the morphology and surface structure of the catalyst. As shown in Fig. 6b, Gewirth et al. used 3,5-diamino-1,2,4-triazole (DAT) as an electrodeposition inhibitor to control the morphology of copper alloys, and obtained catalyst with a high specific surface area and porous structure.37 Some studies have found that additives can form complexes with metals to participate in the catalytic process while regulating the morphology of the catalysts. Xu et al. investigated the electrodeposition of copper phosphate complex by modifying the electrode with phosphate ligands.41 Phosphate anions form complexes with free Cu(II), which compete with the electrodeposition process, resulting in dendrites replacing aggregates. Moreover, Lin et al. used EDTA as an additive for both structural induction and ligand effect, and then creatively generated ligand-modified porous hollow copper through the electrodeposition process.42 The charge and space interaction between EDTA and OCCO adsorbent is helpful to stabilize the lower activation barrier and facilitate the formation of ethylene.
The choice of substrate also has a great influence on the performance of the catalyst; the most commonly used substrates are carbon paper-based gas diffusion layer40,55 and metal.24,52–54 Different substrates can result in different growth orientations of catalysts. As shown in Fig. 3a, the dendrite morphology of Cu is formed on both Ag and Pt substrates, but its properties are quite different. When the substrate was Pt, the HER was severe due to the exposure of the substrate. On the contrary, the exposure of Ag increased the production of CO, and the special acicular structure enhanced the selectivity of the C2–C3 products.
It is undeniable that additives have a non-negligible effect on the morphology and performance of catalysts. However, a reserve system that integrates theoretical guidance may allow us to make better use of them. Recently, Wang et al. provided a new path for additive selection and optimization by combining experiment and theory with efficient data analysis through machine guidance (Fig. 6c).43 They indicate that the Sn salt can be used as an important additive for the production of CO and HCOOH, while aliphatic alcohols can promote the formation of Cu2O cubes in the electrodeposition process, which tends to produce C2+ products.
There are many influencing factors of electrodeposition, due to its huge technical parameter space. In addition to the above-mentioned factors, deposition time,44 pH45 and other factors also have a non-negligible influence. The huge parameter space means infinite possibilities, but also one of the biggest challenges.
SEM can be used to observe the microscopic morphology of substances, and at the same time, it can also be used to analyze the composition of micro-areas of substances. Fig. 7a shows the SEM images of mesoporous copper foam deposited on the Cu substrate at different deposition times.46 The deposition rate is limited by the mass transport of metal ions and the mobility of adsorbed atoms on the electrode surface.
Fig. 7 (a) SEM micrographs showing the changes of surface pore size and dendrite size with deposition time. Reproduced with permission.46 Copyright 2021, American Chemical Society. (b) HRTEM images of the Cu–In-30 catalyst, SEM image of the Cu–In-30 catalyst, and the corresponding EDX elemental maps. Reproduced with permission.47 Copyright 2021, American Chemical Society. |
A HR-TEM (high resolution transmission electron microscope) can be employed to observe the crystal plane, so as to calibrate the crystal plane orientation or the growth direction of the material. Fig. 7b shows the TEM image of the Cu–In catalyst.47 In the enlarged local region, the characteristic space of the lattice is observed, which is 0.27 nm and fits well with the indium(101) plane. The morphology and element distribution are closely related to the electrodeposition conditions, and the properties of the catalyst have a huge impact on the performance.
X-Ray diffraction (XRD) is one of the most basic structural characterization methods, mainly used for phase analysis. Fig. 8a-I shows the XRD patterns of the electrodeposited CuAg catalyst in different states, and the transformation of metal and oxide was analyzed, providing direct evidence of the activation of the catalyst under thermal annealing.59Fig. 8b shows the XRD result of AgCu-10 and AgCu-50 at different deposition times.48 The main phases of the catalyst are Cu2O and Ag. The peaks with different diffraction angles represent different crystal planes, and the intensity of crystallization peaks increases with the increase of the deposition time.
Fig. 8 (a) (I) XRD patterns of the as deposited Ag15Cu85 foam, the annealed foam (12 h at 200 °C), and OD-Ag15Cu85 (after 1 h CO2RR at −1.0 V vs. RHE); (II and III) corresponding XPS of the bimetallic foam. Reproduced with permission.59 Copyright 2020, Elsevier. (b) XRD patterns of AgCu film electrodeposited. Reproduced with permission.48 Copyright 2019, American Chemical Society. (c) XPS spectra of electro-redeposited (ERD) copper before and after the reaction. Reproduced with permission.49 Copyright 2018, Macmillan Publishers Limited. |
Since XRD is only sensitive to reveal the bulk phase of the long-range translation order, the complementary X-ray photoelectron spectroscopy (XPS) analysis is more sensitive to the chemical state of the catalyst surface. Fig. 8a-II and III describe the Cu 2p and Ag 3d nuclear level emissions of bimetallic catalyst materials at different stages of preparation and use.59 XPS spectra of silver foil and copper foil samples are also provided as reference. Apparently, Cu(II) species already existed on the deposited foam. As shown in Fig. 8c, dicopper chloride trihydroxide is used as a precursor for carbon dioxide reduction.49 It can be seen that there is almost no Residual Cl ion after the reaction, and the strength of oxygen after the reaction is also significantly reduced, indicating that CuO has been reduced. However, it is difficult to distinguish Cu2O from Cu on XPS after reaction. Further analysis of X ray absorption spectrum (sXAS) can prove the existence of Cu+. The effective combination of various characterization methods can make us better obtain the properties and changes of catalyst, so as to further study its catalytic mechanism. It can better guide researchers to synthesize catalysts.
With the development of CDRRs, traditional characterization techniques are unable to meet the increasing needs. In situ testing technology has gradually entered the core area of scientific research. For example, operando hard X-ray absorption spectroscopy (hXAS) can be used to monitor the formation and transformation of catalysts in real time during the test, and even observe the exposure of crystal planes.50 To monitor the specific process of CDRRs, in situ surface-enhanced Raman spectroscopy (SERS) can be used to capture the appearance of important intermediates, such as the peaks of Cu–CO.75 With the progress and popularization of in situ characterization technology, it is believed that this will greatly promote the research of CDRRs.
Electrocatalyst | Preparation method | Electrolyte | Potential (vs. RHE) | Product | FE (%) | J(mA cm−2) | Stability | Ref. |
---|---|---|---|---|---|---|---|---|
Cu (100)-rich copper | In situ electrodeposition | 1 M KOH | −0.38 V to −0.74 V | C2+ | 90 | 520 | 65 h | 50 |
Porous 3D Cu skeletons | Electrodeposition | 0.5 M KHCO3 | −1.1 V | C2 (C2H4, C2H6) | 29.1 | — | — | 51 |
Nanoscale Ag grains (40–100 nm) | Galvanostatic electrodeposition | 0.5 M KHCO3 | — | CO | Over 90 | 14 | — | 52 |
Ag foam | Galvanostatic electrodeposition | 0.5 M KHCO3 | −1.5 V | CH4 | 51 | — | 5 h | 53 |
0.5 M KHCO3 | −0.8 V | CO | 90 | — | 70 h | |||
Sn-DT GDE | Potentiostatic electrodeposition | 1 M KHCO3 | −0.76 V | HCOOH + CO | 91 | 14 | 72 h | 55 |
Zn dendrite | Galvanostatic electrodeposition | 0.5 M KHCO3 | −0.9 V | CO | 80 | 4 | — | 56 |
Bi-CMEC | Potentiostatic electrodeposition | Ionic liquid | — | CO | ≈95 | 5.51 | — | 16 |
CuxZn | Galvanostatic electrodeposition | 0.1 M KHCO3 | −1.05 V | C2H6O | 29.1 | 8.2 | 5 h | 58 |
Cu@Sn | Galvanostatic electrodeposition | 0.5 M KHCO3 | −0.93 V | HCOOH | ≈100 | 16.52 | 15 h | 60 |
Cu–Sn | Electrodeposition–calcination | 0.1 M KHCO3 | −1.0 V | HCOOH | 82 | 18.9 | 42 h | 62 |
SnCu | Potentiostatic electrodeposition | 0.5 M KHCO3 | −1.2 V | HCOOH | 78 | 88 | 250 min | 63 |
In55Cu45 | Electrodeposition | 0.5 M KHCO3 | −1.0 V | HCOOH | 96.8 | 8.9 | 30 h | 65 |
Cu–Pd | Pulse electrodeposition | 0.1 M KHCO3 | −1.2 V | CH4 | 32 | — | — | 30 |
Cu–Pd | Galvanostatic electrodeposition | 0.1 M KCl | −1.2 V | C2H4 | 45.2 | 17.4 | — | 67 |
CuBi | Co-electrodeposition | 0.5 M KHCO3 | −1.07 V | HCOOH | 98.3 | 56.6 | — | 68 |
GB-Cu | Potentiostatic electrodeposition | — | −1.0 V | C2 | 70 | 52 | 180 min | 72 |
Cu | Electrodeposition | 0.1 M KHCO3 | −1.1 V | C2H4 | 27.8 | 11.8 | 12 h | 73 |
Cu foam | Galvanostatic electrodeposition | 0.1 M NaHCO3 | −0.98 V | C2H4 | 26 | 60 | — | 74 |
Cu–P1 | Co-electrodeposition | 10 M KOH | −0.47 V | C2H4 | 87 | — | — | 75 |
Fig. 9 (a) Schematic diagram of crystal plane distribution when covered by different intermediates. Reproduced with permission.50 Copyright 2020, Springer Nature. (b) Preparation and catalytic performance of silver nanofoam. Reproduced with permission.53 Copyright 2018, American Chemical Society. (c) SEM image and performance distribution diagrams of zinc catalysts. Reproduced with permission.56 Copyright 2015, American Chemical Society. (d) Cyclic voltammogram (CV) in 1.0 M HCl (aq.) and 0.5 M KBr (aq.) containing 20 mM Bi3+ and SEM image of a Bi-modified glassy carbon electrode (GCE). Reproduced with permission.16 Copyright 2013, American Chemical Society. |
Despite the high activity of noble metals, low-cost metals have gained more attention to implement applications on a large scale driven by cost-effectiveness. For example, Jiao et al. reported a nanostructured Zn dendrite electrocatalyst by the electrodeposition method (Fig. 9c), which not only reduces the formation of surface oxide layer, but also creates a highly active catalyst with dendritic.56 At an electrodeposition rate of 1.0 A cm−2, Zn dendrites with highly branched nanostructures can be formed. Under environmental conditions, dendrite Zn catalyst has significant electrochemical CO2 reduction performance, and its activity is about 3 times higher than that of Zn foil, which is attributed to its higher active surface area. Rosenthal and his team electrodeposited cheap Bi material onto glassy carbon electrodes (Fig. 9d).16 The catalyst can be used with ionic liquids to effectively convert CO2 to CO at an overpotential of less than 0.2 V, and the FE is about 95%. The interface between Bi0 and Bi3+ sites may play a role in stabilizing CO2˙− intermediates.
Consequently, as a simple and effective method for preparing catalysts, electrodeposition has been successfully applied to the CDRRs of metals and has become one of the preferred methods for the preparation of catalysts by researchers. As the method matures, the combination with other technologies gradually expands its application.5 It is foreseeable that electrodeposition will gradually develop towards refinement and industrialization.
At present, most research studies focus on the combination of Cu with another metal to improve the CDRR performance, such as CuZn,58 CuAg,17,59 CuSn,28,60–63 CuPb,64 CuIn,47,65,66 CuPd,67 CuBi,68etc. In Fig. 10a, Yeo et al. proposed a strategy to compensate for the insufficient CO solubility by introducing CuxZn alloys to catalyze the in situ generation of CO during the CO2RR process.58 CO is weakly adsorbed on the Zn site and easily diffuses into the Cu matrix, increasing the concentration of *CO intermediate, and the intermediate bonds with *CH2 to form *COCH2 to further generate ethanol. At −1.05 VRHE, Cu4Zn can reach the FE of ethanol (29.1%) and the current density (−8.2 mA m−2). Moreover, Gewirth fabricated a catalyst with a high specific surface area by electrodepositing CuAg alloy films in an additive bath.17 The faradaic efficiencies of C2H4 and C2H5OH are close to 60 and 25% (Fig. 10b), respectively. Ag promotes the formation of Cu2O, which is beneficial to improve the production efficiency of CO and C2H4. Moreover, Strasser et al. tuned the selectivity and efficiency of electrochemical CO2 reduction by controlling the inhibition of the hydrogen evolution reaction channel.64 They demonstrate an unusually high selectivity for formate (HCOO−) over a wide range of overpotentials when a small amount of sub-monolayer Pb atoms is deposited on the Cu surface. In short, although there have been many studies on binary alloys of Cu with enhanced selectivity, the research on commercialization is relatively lacking and relevant research is urgently needed.
Fig. 10 (a) Schematic diagram of ethanol production from CuZn alloy. Reproduced with permission.58 Copyright 2016, American Chemical Society. (b) Schematic diagram of the production of C2 products from CuAg alloys. Reproduced with permission.17 Copyright 2018, American Chemical Society. (c) Schematic diagram of efficient CO production from AgZn alloy. Reproduced with permission.27 Copyright 2019, Elsevier Inc. |
Compared with the binary alloys of copper, combination studies of other metals are rare. One of the reasons is that it lacks the ability to produce hydrocarbons and the main research is on CO27,70 and HCOOH.69 The extremely high selectivity may give it a huge potential to industrialize earlier. Fontecave et al. optimized the Ag content, porosity, thickness and specific surface area by adjusting the electrodeposition parameters to prepare a AgZn dendritic electrode.27 The selectivity of CO2 to CO conversion was higher than 91%, and remained above 90% on an average within 40 h. As shown in Fig. 10c, after increasing the pressure of CO to 9.5 par, the current density of CO2 to CO can reach 286 mA cm−2. For cost consideration, Li et al. used electrodeposition technology to deposit cheap Bi and Sn on the copper mesh to obtain similar pine needle-shaped dendritic structured BiSn metal electrodes.69 The Bi5Sn60 electrode has good catalytic activity for CO2 reduction at −1.0 VRHE, the FE of formic acid is as high as 94.8%, the partial current density is 34 mA m−2, and the yield is 636.3 μmol cm−2 h−1. At a constant potential of −1.0 V, the alloy was stable for 20 h while maintaining a high FE. The good performance is attributed to the large active surface area and abundant active sites of the catalyst, as well as the fast charge transfer brought by the optimized structure.
The combination of binary alloys has greatly improved the performance and stability of catalysts. However, there have been many research studies on binary alloys, but most of them are attributed to the synergistic effect of alloys. The effect of the distance between different metal active sites in bimetallic component catalysts on the catalytic activity is not yet clear,71 and deep research at the atomic level may provide further understanding of binary alloys, and also help us obtain better theoretical guidance to prepare alloys.
Fig. 11 (a) HRTEM image of grain boundary-rich copper catalyst (GB-Cu) and its catalytic performance. Reproduced with permission.72 Copyright 2020, American Chemical Society. (b) Schematic diagram of poly-amide modified copper foam electrodes. Reproduced with permission.74 Copyright 2018, American Chemical Society. (c) Schematic illustration of poly-N-(6-aminohexyl)acrylamide (P1) and Cu co-electroplating on the gas diffusion layer (GDL). Reproduced with permission.75 Copyright 2021, Springer Nature. |
(2) Some additives can also be adsorbed on metals through bonding during the deposition process, or form complexes with metals to participate in catalysis. For example, Andreoli et al. obtained a polyacrylamide-modified Cu electrode by electrodepositing copper in an additive-added bath (Fig. 11b).74 DFT calculations indicated that polyacrylamide was adsorbed on copper through oxygen on the carbonyl group. The additive also promotes the adsorption of CO molecules, thereby enhancing the generation of C2H4. Appropriate additives can promote the progress of the CDRR reaction.
(3) Adding additives that alter the stability of the intermediates on the electrode surface can increase the CDRR activity. Unfortunately, small molecules decorated on the catalyst surface are usually desorbed and removed in the flow cell. Therefore, the co-deposition of polymer and copper on the electrode surface can maintain the required entrainment function. To understand the effect of polymers on the electrocatalytic activity, Gewirth et al. co-deposited poly-n-(6-aminohexyl)acrylamide and copper to make Cu-polymer electrodes (Fig. 11c).75 In 1 M KOH, the FE of ethylene reaches 72% at −0.97 VRHE, and the partial current density of ethylene can reach −312 mA cm−2. Amino groups on the electrode surface can change the reactivity and surface pH to capture CO2, resulting in a higher local concentration of CO2 on the surface.
The use of additives affects the electrodeposition process and even the catalyst performance to a great extent, but its limitations are rarely mentioned in the literature. First, the excessive use of catalysts deviates from green electrochemistry. Second, the position of the additive attached to the catalyst is random and easy to fall off, resulting in its general stability. Therefore, a green, easy-to-recycle, and stable additive may provide a reference for the selection of additives.
The concept of entropy was also introduced into binary alloys, Takeguchi et al. proposed an entropy-based adsorption theory that alloys with random distributions can weaken the adsorption of *CO.78 Therefore, high-entropy state CuSn alloys (Cu6Sn5) may not be suitable for *CO adsorption, while low-entropy state CuSn alloys may provide enhanced *CO adsorption capacity and subsequent enhanced C2 product selectivity. Based on this, Zheng et al. developed a bimetallic low-entropy Cu3Sn catalyst with high efficiency for CO2 reduction to ethanol, with an FE of 64%.79 At an industrial current density of −900 mA cm−2, the Cu3Sn catalyst exhibits excellent stability over 48 h.
As a brand-new alloy system, high-entropy alloys have great advantages in material stability, strength, and electrochemical properties. At present, the preparation of high-entropy alloys by electrodeposition for CDRRs is extremely rare. Reasonable design and preparation of ideal high-entropy alloys have broad application prospects in CDRRs.
As we know, the market for methane, ethane, methanol, formic acid and ethylene is huge and in short supply (Fig. 13a). The advancement of carbon neutrality is also imperative. However, we lack a system of business models to integrate which products are our identified goals, and second, the huge cost of electrocatalytic CO2 reduction has also become a hindrance to commercialization. Electrolyzers with high power, high selectivity and stability are what we must explore. For example, Gewirth et al. electrodeposited CuSn-DAT catalyst on a carbon paper-based gas diffusion layer (GDL) with 3,5-diamino-1,2,4-triazole (DAT) as the buffer.40 The CuSn-DAT electrode exhibits the highest FE for CO (∼90% at −0.4 VRHE) and C2H4 (∼60% at −0.8 VRHE) production and high current density (−225 mA cm−2 at −0.8 V) in a flow cell. As shown in Fig. 13b, the flow cell consists of anode, cathode and electrolyte flow channels. When the reaction takes place, CO2(g) is supplied to the cathode side, where it diffuses to the electrocatalyst to be reduced; OER occurs at the anode, and is released into the air. As shown in Fig. 13c, Sargent et al. deposited copper using carbon-based GDL and polymer-based GDL as substrates, respectively.81 In strongly basic media, the abrupt interface formed on the catalyst enables ethylene incorporation to progress. The bias current density of ethylene at −0.67 VRHE reached 473 mA cm−2. GDL is a porous material, and catalysts are immobilized on these layered materials to make gas diffusion electrodes (GDEs). The current density is highly important for industrialization (Fig. 13a).82 Laboratory-scale flow cells provide an opportunity for further efficient CDRRs and are gaining increasing attention. This is a critical step towards carbon neutrality and one of CDRR's paths towards industrialization. It is believed that with the continuous in-depth research on flow cells, industrial-scale CDRRs will be realized in the near future.
Fig. 13 (a) An overview of the market for CDRR products and the application of flow cell. Reproduced with permission.82 Copyright 2018, American Chemical Society. (b) Schematic diagram of the flow tank structure. Reproduced with permission.40 Copyright 2019, American Chemical Society. (c) Schematic diagrams of flow cell cathode and the catalytic performance. Reproduced with permission.81 Copyright 2018, American Association for the Advancement of Science. |
In addition to the attempts on electrolyzers, the researchers also considered various factors conducive to industrialization, such as the production of CO under high pressure,27 the large-area electrodes,83 the recovery of electrodeposition waste liquid,84 and the use of low-sink metals to efficiently prepare CO.85,86 For example, large-area gas diffusion electrodes are of great significance. Kim et al. fabricated large-area (25.5 and 136 cm2) Ag gas diffusion electrodes by electrodeposition. And it was successfully combined with MEA-type CO2 electrolyzer.83 The preparation of large-area electrodes has more stringent technical requirements, and it is necessary to accurately control and compare factors such as electrode system, electrode arrangement, deposition current and deposition time. In this way, a catalyst with uniform deposition and good morphology can be obtained to ensure that its catalytic activity reaches a high level. The 136 cm2 Ag GDE fabricated under optimal conditions has an effective geometric area of 107.44 cm2 in an MEA-type CO2 electrolyzer, giving potential-dependent CO conversion efficiencies of 41.99–57.75% at Vcell = 2.2–2.6 V. Although the performance of the catalyst has not reached the high level of laboratory research, and it also faces many technical problems, it is undoubtedly an effective attempt for commercialization. The next development direction should be focused on solving key technical challenges, such as the optimization and update of electrolyzers.87,88 Excellent technologies from various fields need to be reasonably combined to overcome difficulties in the industrialization of CDRRs.
Undoubtedly, the preparation of catalysts by electrodeposition has many advantages. Simultaneously, different experimental parameters can create different catalysts in electrodeposition technology. Experimental parameters such as current density, electrolyte, pH, and additives have their own influence and play a crucial role in obtaining an ideal catalyst, which is also one of the biggest challenges posed by electrodeposition technology.
We also outline the application of electrodeposition in CDRRs. The exploration of additives, units, and binary metals has gradually deepened, while multi-element and even high-entropy still need a long way to be explored. According to the current research progress and some gaps in the field, we give the following suggestions:
(1) Given the low cost and easy scalability of electrodeposition, it is attractive for the preparation of electrochemical CO2 reduction catalysts. In order to achieve industrialization, it is necessary to overcome the shortcomings of traditional electrodeposition lacking metering control, establish a complete database, accurately adjust electrochemical methods and experimental parameters, and expand the relatively mature technology in the laboratory to large-scale experiments.
(2) Surface modification is an important strategy to modulate the selectivity, and it is also a complex engineering process. Modifications of amines, halogens, and polymers have been reported one after another. By combining theoretical calculation simulations and experiments, the number of effective modified molecules can be expanded faster and more accurately, providing a feasible and effective strategy for improving the C2+ product efficiency of CDRRs.
(3) The limitations of traditional electrodeposition technology need to be overcome and a new catalyst system should be developed, for example, the preparation of high-entropy alloys mentioned in this article, the preparation of single-atom catalysts, etc. Wang et al. introduced the synthesis and application of high-entropy alloys in detail.89 Zeng et al. successfully obtained a variety of single-atom HER catalysts using electrodeposition through different metal precursors and supports.90 Sun et al. summarized the applications and preparations of single-atom catalysts in CDRRs, and introduced the relationship between their structures and properties.91 In addition, 2D nanosheets have abundant low-coordination atoms and a large specific surface area, which is one of the candidates for electrochemical catalysis.92 It is believed that combining electrodeposition technology with new materials holds promise for CDRRs.
(4) There are many factors that affect the selectivity and efficiency of electrodeposition catalysts, including material composition, crystal structure, microscopic morphology, electronic state, etc. Making full use of advanced characterization and measurement techniques (in situ optics, X-ray) and theoretical calculations to detect the actual deposition operation and even the process of CDRRs is of great help in further understanding the relationship between materials and reaction mechanisms. In particular, in the face of the complex reaction process, the catalyst itself undergoes a large structural evolution, and we need to reveal the key influencing factors. Advanced technology will undoubtedly help our research in depth.
(5) In the face of increasingly high industry requirements, the reference and cooperation between different technologies may bring electrodeposition technology to a new level, for example, in terms of technology, plasma treatment of the substrate before deposition to further increase the surface roughness of the substrate or to obtain a substrate with doped properties. The electrodeposited material is further calcined to obtain a more stable material. In terms of theory, in the age of information data, machine learning has become an inevitable path. Combining the guidance of machine learning with the effective screening and preparation of catalysts will be an effective way to develop high-performance catalysts.
(6) In the carbon neutrality, there is no doubt that CDRRs are one of the promising areas to settle energy and environmental problems. With the in-depth study, current density, energy efficiency, CO2 utilization and even economic benefits93 have gradually become the focus for scientific researchers. Electrodeposition technology is one of the most cost-effective synthesis methods, so it has become an excellent choice for catalysts. In order to adapt to new demands, electrodeposition technology needs to be integrated with GDEs and applied in the state-of-the-art device systems. Only this way can make it one of the best choices for future industrialization.
This journal is © The Royal Society of Chemistry 2022 |