Nanocone-Modified Surface Facilitates Gas Bubble Detachment for High-Rate Alkaline Water Splitting

Abstract

Alkaline water splitting (AWS) is one of the most attractive technologies for green hydrogen production. In comparison to the acidic proton exchange membrane (PEM), AWS offers greater flexibility in using non-platinum group metal catalysts and could generate higher-purity hydrogen. However, commercial AWS systems are normally operated at a lower current density (~400 mA cm-2) than PEM electrolyzers. To rapidly generate hydrogen at an industrial scale, it is critical to boost the operating current density of AWS to a level of ~1000 mA cm-2. Nevertheless, the significant amount of gas bubbles generated during high-rate AWS could be detrimental to the process. Bubbles can block the catalysts’ active site, hinder electrolyte diffusion, and increase Ohmic resistance, thus deteriorating the reaction rate and restricting the cell voltage efficiency. The detachment of gas bubbles may also damage the catalyst layer. In this study, we demonstrate a general strategy for facilitating bubble detachment by modifying the nickel electrode surface with nickel nanocone nanostructures, which turns the surface into underwater superaerophobic. The simulation and experimental data show that bubbles take a considerably shorter time to detach from the nanocone-modified nickel foil than the unmodified foil. As a result, these bubbles also have a smaller detachment size and less chance for bubble coalescence. The nanocone-modified electrodes, including nickel foil, nickel foam, and 3D-printed nickel lattice, all show substantially reduced overpotentials at 1000 mA cm-2 compared to their pristine counterpart. The electrolyzer assembled with two nanocone-modified nickel lattice electrodes retains >95% of the performance after testing at ~900 mA cm-2 for 100 hours and the surface NC structure is also well preserved, demonstrating its excellent electrochemical and mechanical stability at high current density. Our findings offer an exciting and simple strategy for enhancing the bubble detachment and, thus, the electrode activity for high-rate AWS.