The Stability of Electrodes with Intermediate Layer-Induced Catalytic Layer-Matrix Layer Interfaces in Chlorine...

Area of Science:

• Electrochemistry
• Materials Science
• Chemical Engineering

Background:

• Industrial chlorine-hydrogen co-production is vital for sustainable chemical manufacturing.
• Conventional Dimensionally Stable Anode (DSA) catalysts face limitations in activity and long-term stability, hindering energy efficiency.
• Developing robust and efficient anodes is critical for advancing electrolytic processes.

Purpose of the Study:

• To engineer a highly active and stable catalyst for industrial chlorine-hydrogen co-production.
• To overcome the limitations of current DSA anodes in terms of energy consumption and operational lifespan.
• To investigate the structure-activity relationship of a novel heterostructure catalyst.

Main Methods:

• Synthesis of a RuSnOₓ/IrTaOₓ catalyst with interlayer anchoring on a titanium mesh substrate using an industrial-scale method.
• Electrochemical performance evaluation, including chlorine production activity and overpotential measurements.
• Accelerated durability testing at high current densities (2 A cm⁻²).
• In situ Raman and X-ray photoelectron spectroscopy (XPS) for mechanistic analysis.

Main Results:

• The synthesized RuSnOₓ/IrTaOₓ catalyst demonstrated high chlorine production activity with an overpotential of 79 mV at 100 mA cm⁻².
• Exceptional stability was achieved, with the catalyst remaining stable for 1000 hours during accelerated durability tests at 2 A cm⁻².
• The intermediate IrTaOₓ layer was found to enhance Ru oxidation state and activity, while low-valent Ir protected against Ru leaching and substrate corrosion.

Conclusions:

• The developed RuSnOₓ/IrTaOₓ catalyst offers a promising solution for durable and efficient industrial chlorine-hydrogen co-production.
• The multifaceted stabilization mechanism involving the intermediate layer significantly enhances catalytic performance and longevity.
• This work provides insights into designing advanced electrocatalysts for sustainable electrochemical processes.