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Seawater electrolysis for hydrogen production represents a substantial opportunity to curtail production expenditures and exhibits considerable potential for various industrial applications. Platinum-based precious metals exhibit excellent activity for water electrolysis. However, their limited reserves and high costs impede their widespread use on a large scale. Single-atom catalysts, characterized by low loading and high utilization efficiency, represent a viable alternative, and the development of simple synthesis methods can facilitate their practical application. In this work, we report the facile synthesis of a single-atom Pt-loaded NiCoFeSx (Pt@NiCoFeSx) bifunctional catalytic electrode using a simple impregnation method on a nickel foam substrate. The resulting electrode exhibits low overpotentials for both HER (60 mV@10 mA cm−2) and OER (201 mV@10 mA cm−2) in alkaline seawater electrolytes. When incorporated into a seawater electrolyzer, this electrode achieves a direct current energy consumption of only 4.18 kWh/Nm3H2 over a 100 h test period with negligible decay. These findings demonstrate the potential of our approach for industrial-scale seawater electrolysis. [ABSTRACT FROM AUTHOR]

Low-energy consumption seawater electrolysis at high current density is an effective way for hydrogen production, however the continuous feeding of seawater may result in the accumulation of Cl−, leading to severe anode poisoning and corrosion, thereby compromising the activity and stability. Herein, CoFeAl layered double hydroxide anodes with excellent oxygen evolution reaction activity are synthesized and delivered stable catalytic performance for 350 hours at 2 A cm−2 in the presence of 6-fold concentrated seawater. Comprehensive analysis reveals that the Al3+ ions in electrode are etched off by OH− during oxygen evolution reaction process, resulting in M3+ vacancies that boost oxygen evolution reaction activity. Additionally, the self-originated Al(OH)n− is found to adsorb on the anode surface to improve stability. An electrode assembly based on a micropore membrane and CoFeAl layered double hydroxide electrodes operates continuously for 500 hours at 1 A cm−2, demonstrating their feasibility in brine electrolysis. Developing high-performance electrodes for catalyzing brine oxidation is essential for cost effective hydrogen production. Here, this study reveals the self-protective mechanism of CoFeAl layered double hydroxides, enabling stable operation in the presence of concentrated seawater at 2 A cm−2. [ABSTRACT FROM AUTHOR]

Water electrolysis is a crucial technology in the production of hydrogen energy. Due to the escalating industrial demand for green hydrogen, the required electrode size for a traditional alkaline water electrolyzer has been increasing. Numerous studies have focused on developing highly active oxygen evolution reaction (OER) catalysts for water electrolysis. However, there remains a significant gap between the microscale synthesis of catalysts in laboratory settings and the macroscale preparation required for industrial scenarios. This challenge is particularly pronounced in the synthesis of sizable self-supported electrodes. In this work, we employed a commercially available Raney Ni-coated Ni mesh as a precursor material to fabricate a self-supported NiFe(OH)x@Raney Ni anode with a substantial dimension exceeding 300 mm through a straightforward immersion technique. The as-prepared electrode exhibited remarkable electrocatalytic OER activity, as an overpotential of only 240 mV is required to achieve 10 mA cm−2. This performance is comparable to that of NiFe-LDHs synthesized via a hydrothermal method, which is difficult to scale up for industrial applications. Furthermore, the electrode demonstrated exceptional durability, maintaining stable operation for over 100 h at a current density of 500 mA cm−2. The large-scale electrode displayed consistent overpotentials across various areas, indicating uniform catalytic activity. When integrated into an alkaline water electrolysis device, it delivered an average cell voltage of 1.80 V at 200 mA cm−2 and achieved a direct current hydrogen production energy consumption as low as 4.3 kWh/Nm3. These findings underline the suitability of electrodes for industrial scale applications, offering a promising alternative for energy-efficient hydrogen production. [ABSTRACT FROM AUTHOR]