High-Throughput Screening of Co–Fe–Ni Electrocatalysts for High-Current-Density Water Electrolysis

Optimizing Water Splitting: A High-Throughput Approach to Co–Fe–Ni Electrocatalysts

Published in: ChemCatChem (2024)

DOI: 10.1002/cctc.202401749

Authors: Rajini P. Antony, Ridha Zerdoumi, Sascha Saddeler, Olga A. Krysiak, Lars Banko, Alfred Ludwig, Wolfgang Schuhmann

Efficient Water Electrolysis Begins with Smarter Catalysts

Electrochemical water splitting offers a clean and scalable method for hydrogen production, but the oxygen evolution reaction (OER) remains a major bottleneck. In this study, researchers introduce a high-throughput screening strategy to identify high-performance Co–Fe–Ni alloy electrocatalysts for water electrolysis at industrial-level current densities.

High-Throughput Discovery

Using a scanning droplet cell and thin-film materials libraries, over 400 compositions within the Co–Fe–Ni system were rapidly screened. The study identified two regions of high catalytic activity, with the best-performing composition being Co₁₇Fe₂₅Ni₅₈, which demonstrated superior OER activity and long-term stability.

Scalable Electrode Fabrication

Top-performing compositions were synthesized via electrodeposition onto nickel foam. This method is not only cost-effective and scalable but also reproducible, making it ideal for industrial applications. Surface and electrochemical characterizations confirmed the formation of uniform, active catalyst layers.

Record Performance Under Harsh Conditions

• Co₁₇Fe₂₅Ni₅₈ achieved a stable current density of 1 A cm⁻² at ~1.9 V, and up to 2.5 A cm⁻² at 1.55 V vs RHE.

• The catalyst showed minimal degradation even after 30 hours of continuous operation with shutdown-restart cycling.

• Raman spectroscopy revealed the formation of the highly active γ-NiOOH phase at higher potentials, which plays a key role in OER activity.

Why It Matters

This work provides a complete, scalable approach — from composition screening to MEA-based flow cell testing — for developing robust electrocatalysts. The findings bridge the gap between lab-scale research and practical implementation in green hydrogen production systems.