The development of alternative routes for ammonia (NH3) synthesis with high Faradaic efficiency (FE) is crucial for energy conservation and to achieve zero carbon emissions. Electrocatalytic nitrate (NO3-) reduction to NH3 (e-NO3RRA) is a promising alternative to the energy-intensive, fossil-fuel-driven Haber-Bosch process. The implementation of this innovative NH3 synthesis technique requires an efficient electrocatalyst and in-depth mechanistic understanding of e-NO3RRA. In this study, we developed an ultrathin sheet (µm) iron-nickel nanoflower alloy through electrodeposition and used it for e-NO3RRA under alkaline conditions. The prepared Fe-Ni alloy exhibited an FE of 97.28 ± 1.36% at -238 mVRHE with an NH3 yield rate of 3999.1 ± 242.59 mg h-1 cm-2. Experimental electrolysis, in-situ Raman spectroscopy, and density functional theory calculations showed that the adsorption and reduction of NO3- to NO2- occurred on the Fe surface, whereas subsequent hydrogenation of NO2- to NH3 occurred preferentially on the Ni surface. The catalysts exhibited comparable FE for at least 10 cycles, with a long-term stability of 216 h. Electron paramagnetic resonance results confirmed that adsorbed hydrogen was consumed during e-NO3RRA. This work introduces a sustainable, robust, and efficient Fe-Ni alloy electrocatalyst, offering an environmentally friendly approach for synthesizing NH3 from NO3--contaminated water.
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