High catalytic performance of CuCo/nickel foam electrode for ammonia electrooxidation

Electrocatalytic Ammonia Oxidation Reaction: Selective Formation of Nitrite and Nitrate as Value-Added Products

Ammonia (NH3) plays a pivotal role as a hydrogen carrier, offering a carbon-free energy alternative for sustainable energy systems. The ammonia electrooxidation reaction (AmOR) emerges as a promising avenue to leverage NH₃ in energy conversion and environmental applications. This review explores the multifaceted importance of NH3 oxidation through three primary strategies: its integration into fuel cell technology for clean energy generation, its use in wastewater treatment for ammonia removal, and its application in electrolyzer setups for producing value-added products. Special emphasis is placed on oxidizing NH3 to nitrite (NO2 -) and nitrate (NO3 -) in electrolyzers as a potential alternative to the energy-intensive Ostwald process. The review highlights recent advances in catalyst development for efficient NO2 -/NO3 - synthesis, the influence of the pH on reaction selectivity, and various reported experimental AmOR solutions. By addressing these critical aspects, this work aims to underscore the potential of NH3 oxidation in electrolyzers for sustainable energy solutions. Potential future research directions and challenges are also discussed.

Ammonia electro-oxidation on nickel hydroxide: phases, pH and poisoning

Nickel hydroxide is a leading alternative to platinum group metals for electrocatalysis of the ammonia oxidation reaction (AOR), an important process for energy conversion and environmental remediation. Nevertheless, the dependence of AOR electrocatalysis on the different crystalline phases at the electrode surface (α-Ni(OH)2/γ-NiOOH vs. β-Ni(OH)2/β-NiOOH) has never been investigated. Herein, the crystalline β-Ni(OH)2 and the disordered α-Ni(OH)2 were synthesized and characterized by XRD, HRSEM, and Raman and FTIR spectroscopies. The respective electrocatalytic activity of the two phases was analysed at a broad range of ammonia concentrations (0.01-2 M) and pH values (11-13). Both phases electrocatalyze the oxidation of NH3 to N2, as proven by online mass spectrometry, but the α-Ni(OH)2/γ-NiOOH couple is more active. At high ammonia concentrations (>1 M), surface poisoning by adsorbed NH3 prevents access to OH-, leading to less NiOOH formation, lower AOR currents, and suppression of the OER side reaction. The poisoning is strong and irreversible on α-Ni(OH)2, as confirmed by soaking experiments. The difference in ammonia adsorption and electrocatalytic activity between the α-Ni(OH)2 and β-Ni(OH)2 emphasizes the importance of understanding the phase space of nickel hydroxide electrodes when designing low-cost electrocatalysts for the nitrogen cycle.

Gas Diffusion Electrodes for Electrocatalytic Oxidation of Gaseous Ammonia: Stepping Over the Nitrogen Energy Canyon

As ammonia continues to gain more and more interest as a promising hydrogen carrier compound, so does the electrochemical ammonia oxidation reaction (AmOR). To avoid the liberation of H2 in a reverse Haber-Bosch reaction under release of the energetically more favorable N2, we propose the oxidation of ammonia to value-added nitrite (NO2 -), which is usually obtained during the Ostwald process. We investigated the anodic oxidation of gaseous ammonia directly supplied to a gas diffusion electrode (GDE) using a variety of compositionally different multi-metal catalysts coated on Ni foam under the simultaneous formation of H2 at the cathode. This will double the amount of H2 per ammonia molecule while applying a lower overpotential than that required for water electrolysis (1.4-1.8 V vs. RHE at 50 mA ⋅ cm-2). A selectivity study demonstrated that some of the catalyst compositions were able to produce significant amounts of NO2 -, and further investigations using the most promising catalyst composition Nif_AlCoCrCuFe integrated within a GDE demonstrated up to 88 % Faradaic efficiency for NO2 - at the anode coupled to close to 100 % Faradaic efficiency for the cathodic H2 production.

A Petal-like Structured NiCuOOH-NF Electrode by a Sonochemical Combined with the Electrochemical Method for Ammonia Oxidation Reaction

Direct electrochemical oxidation, as an economical and efficient method, has recently received increasing attention for ammonia-nitrogen wastewater treatment. Developing a low-cost, efficient catalytic electrode is the key to solve the problem of sluggish ammonia oxidation reaction (AOR) kinetics. In this study, a three-dimensional (3D) Ni foam electrode coated with NiCuOOH petal-like cluster structures was prepared using a simple sonochemical method combined with a surface electrochemical reconstruction strategy. This structure has a large surface area and abundant NiCuOOH active sites, giving a good premise for extraordinary electrocatalytic activity of AOR. The results show that the maximum current density for AOR reaches 97.8 mA cm−2 at 0.60 V vs. saturated calomel electrode (SCE). Additionally, 96.53% of NH4+-N removal efficiency and 63.12% of TN removal efficiency were acquired in the electrolysis system based on the NiCuOOH-NF electrode, as well as a good stability for at least 24 h. It is a promising flow-through anode for the clean treatment of ammonia-nitrogen wastewater.

A Survey of Catalytic Materials for Ammonia Electrooxidation to Nitrite and Nitrate

Studies of the ammonia oxidation reaction (AOR) for the synthesis of nitrite and nitrate (NO2/3 - ) have been limited to a small number of catalytic materials, majorly Pt based. As the demand for nitrate-based products such as fertilisers continues to grow, exploration of alternative catalysts is needed. Herein, 19 metals immobilised as particles on carbon fibre electrodes were tested for their catalytic activity for the ammonia electrooxidation to NO2/3 - under alkaline conditions (0.1 m KOH). Nickel-based electrodes showed the highest overall NO2/3 - yield with a rate of 5.0±1.0 nmol s-1  cm-2 , to which nitrate contributed 62±8 %. Cu was the only catalyst that enabled formation of nitrate, at a rate of 1.0±0.4 nmol s-1  cm-2 , with undetectable amounts of nitrite produced. Previously unexplored in this context, Fe and Ag also showed promise and provided new insights into the mechanisms of the process. Ag-based electrodes showed strong indications of activity towards NH3 oxidation in electrochemical measurements but produced relatively low NO2/3 - yields, suggesting the formation of alternate oxidation products. NO2/3 - production over Fe-based electrodes required the presence of dissolved O2 and was more efficient than with Ni on longer timescales. These results highlight the complexity of the AOR mechanism and provide a broad set of catalytic activity and nitrate versus nitrite yield data, which might guide future development of a practical process for the distributed sustainable production of nitrates and nitrites at low and medium scales.

Improved mineralization and total nitrogen reduction by combination of electro-reduction and electro-oxidation for nitrophenol removal

In this work, p-Nitrophenol (p-NP) was electro-chemically removed by using a prepared Co₃O₄/Ti cathode and a BDD anode to achieve the simultaneous reduction of total organic carbon (TOC), total nitrogen (TN) and toxicity. The prepared Co₃O₄/Ti cathode showed higher electro-activity than the Ti cathode towards p-NP reduction with the removal rate higher than 90.6% but without mineralization. The electro-oxidation removed 84.3% of TOC but none of TN. To develop an optimized process for mineralization and TN removal during p-NP electrolysis, the combination of electro-oxidation and electro-reduction were evaluated by using a dual-chamber cell and a single-chamber cell, respectively. As a result of the re-oxidation and re-reduction in the single-chamber cell, the typically used mode of the simultaneous redox, showed a lower removal of TOC and TN than the combination processes as well as an increased toxicity. The TN removal for both combined modes (21.0%-32.9%) was all higher than that of the mode of reduction because the produced inorganic nitrogen such as ammonia and nitrate could be partially oxidized or reduced to nitrogen gas. The results suggested that the combination process could significantly improve the mineralization and TN reduction for p-NP removal, accompanied with 60.3% decrease of acute toxicity for the reduction after oxidation mode.

Nickel foam supported porous copper oxide catalysts with noble metal-like activity for aqueous phase reactions

Contiguous metal foams offer a multitude of advantages over conventional powders as supports for nanostructured heterogeneous catalysts; most critically a preformed 3-D porous framework ensuring full directional coverage of supported catalyst, and intrinsic ease of handling and recyclability. Nonetheless, metal foams remain comparatively underused in thermal catalysis compared to more conventional supports such as amorphous carbon, metal oxides, zeolites and more recently MOFs. Herein, we demonstrate a facile preparation of highly-reactive, robust, and easy to handle Ni foam-supported Cu-based metal catalysts. The highly sustainable synthesis requires no specialized equipment, no surfactants or additive redox reagents, uses water as solvent, and CuCl2(H2O)2 as precursor. The resulting material seeds as well-separated micro-crystalline Cu2(OH)3Cl evenly covering the Ni foam. Calcination above 400 °C transforms the Cu2(OH)3Cl to highly porous CuO. All materials display promising activity towards the reduction of 4-nitrophenol and methyl orange. Notably, our leading CuO-based material displays 4-nitrophenol reduction activity comparable with very reactive precious-metal based systems. Recyclability studies highlight the intrinsic ease of handling for the Ni foam support, and our results point to a very robust, highly recyclable catalyst system.

Optimization of a Hierarchical Porous-Structured Reactor to Mitigate Mass Transport Limitations for Efficient Electrocatalytic Ammonia Oxidation through a Three-Electron-Transfer Pathway

Regulation of fast three-electron-transfer processes for electrocatalytic oxidation of ammonia to nitrogen by achieving efficient generation and utilization of active sites is the optimal strategy in ammonia-containing wastewater treatment. However, the limited number of accessible active sites and sluggish interfacial mass transfer are two main bottlenecks restricting conventional ammonia oxidation configurations. Herein, we develop a macroporous Ni foam electrode integrated with vertically aligned two-dimensional mesoporous Ni₂P nanosheets to create sufficient exposure of active centers. A novel ammonia oxidation reactor with the developed hierarchical porous-structured electrodes was assembled to construct an intensified microfluidic process with flow-through operation to mitigate macroscopic mass transport limitations. The confined microreaction space in the hierarchical porous reactor further promotes spontaneous nanoscale diffusion/convection of the target contaminant to high-valence Ni sites and enhances the microscopic mass transfer. The combined results of electrochemical measurements and in situ Raman spectra showed that the ammonia degradation mechanism results from direct oxidation by the high-valence Ni, significantly different from the conventional indirect active-chlorine-species-mediated oxidation. The optimized reactor achieves high-efficiency three-electron-transfer ammonia conversion with an ammonia removal efficiency of ∼70% from an initial concentration of ∼1400 mg/L and byproduct production of ∼4%, significantly superior to a conversion unit comprising a featureless Ni-based electrode in the immersed configuration, which had >50% byproduct yield. 20 days of continuous operation under variable conditions achieved >90% ammonia degradation performance and an energy consumption of 25.42 kW h kg^-1 N (1 order of magnitude lower than the active-chlorine-mediated process), showing the potential of the reactor in medium-concentration ammonia-containing wastewater treatment.