Fabrication of Iron Phosphide Nanoparticle/Carbon Paper Electrodes Via Electrophoretic Deposition for HER Catalysis

Abstract

As a renewable energy source to replace traditional fossil fuels, hydrogen is a promising sustainable energy carrier due to its eco-friendly nature and high energy density. Although Pt-based materials are widely used as catalysts for generating hydrogen through water electrolysis because of their high catalytic activity, Pt is expensive, and its scarcity hinders the commercialization of large-scale hydrogen production. The development of alternative low-cost materials with low hydrogen evolution reaction (HER) overpotential is the key to achieve low price and highly efficient hydrogen generators such as proton-exchange membrane water electrolysis (PEMWE). Among the numerous candidates of earth-abundant materials, transition metal-based phosphides (TMPs) are suitable for HER applications due to their low toxicity, high electrical conductivity, and catalytic activity. Especially, FeP is in the spotlight as a HER catalyst due to its high catalytic activity in solutions with a wide pH range, and this is a competitive material for large-scale commercial production of hydrogen, since Fe is one of the most abundant elements on earth.In this study, we synthesized the colloidal FeP nanoparticles (NPs) via a hot injection process, so that the pre-synthesized Fe NPs can be converted to FeP NPs through the phosphorization reactions by various phosphorus sources (trioctylphosphine, triphenylphosphite (TPP), tris(diethylamino)phosphine, and tri-n-butylphosphine). Different HER activities were induced by the phase transformation of NPs over the controlled reaction time for the NP samples synthesized with each phosphorus precursor. The FeP synthesized using TPP achieved excellent HER activity with an overpotential of 76 mV at 10 mA cm-2 in 0.5 M H2SO4 as measured by drop casting the catalyst on Ti foil. In terms of the fabrication for the efficient HER electrode, the prepared FeP NPs were deposited on the carbon paper (CP) via electrophoretic deposition (EPD), which is a suitable method for the fabrication of NP films that can be used for various electronic applications. Different morphologies and catalytic activities of the FeP/CP samples were derived by controlling EPD parameters such as mixing ratio of solvents, NP concentration, and deposition voltage. The optimized EPD process lead to excellent HER activity of the FeP/CP with an overpotential of 38 mV and 91 mV at 10 mA cm-2 in 0.5 M H2SO4 and 1 M KOH, respectively. The maximum activity of the catalyst was mainly attributed to the large active surface area and low charge transfer resistance due to the strong contact between the NPs and CP. A PEMWE single cell with the FeP/CP cathode achieved 1.2 A cm-2 at cell voltage of 2.0 V. This study of the EPD procedure for fabricating the NP film from the colloidal NP catalysts contributes to advance manufacturing of HER electrodes for efficient hydrogen generation through water electrolysis.