1. Introduction
The increase in the global population is causing a global energy crisis and a demand for alternative energy sources, such as renewable energy sources [
1,
2,
3]. Consumption of fossil fuels increases the risk of global warming, raising concern among the public [
1,
3] Fossil fuels are limited energy resources compared to renewable energy sources such as solar energy, which is used to generate green hydrogen [
2]. Globally, climate change disproportionately affects the most disadvantaged and vulnerable people [
4]. Sustainable objectives that set the stage for climate change-resistant and low-carbon development were established by the UN Sustainable Development Goals (SDGs) and the Paris Climate Agreement (PCA) in the year 2015 [
4]. The SDGs must be achieved soon to stop climate change and mitigate its effects [
4]. Energy consumption in the end-use sector, namely transport, buildings, and industry, will also have to be considered to achieve time targets for decarbonization because increasing the options available will offer the best opportunity for doing so [
4].
Using fossil fuels as an energy source causes significant pollution. The burning of fossil fuels produces SO
2, which is the cause of acid rain [
3]. Large amounts of greenhouse gasses being released into the atmosphere have caused concern globally, which has led to an international agreement on the reduction of CO
2 emissions known as the Kyoto Protocol [
1,
3].
Hydrogen has become a widespread energy source in recent years, and this is due to it being greener compared to fossil fuels [
3]. Hydrogen is produced by an electrochemical process called electrolysis, where water is split into oxygen and hydrogen [
2]. Hydrogen as an energy carrier has benefits over hydrocarbon fuels, including its high specific energy density, and does not emit pollutants such as CO
2 [
2]. Global hydrogen production for chemical industries, fertilizer production, iron refineries and oil refineries, is estimated to be around 95 MtH
2 per year in 2022 [
5]. The Institute for Energy Economics and Financial Analysis (IEEFA) conservatively estimates that around 2.9 million tonnes of hydrogen per year could be produced from sustainable energy sources by 2030 [
6]. The demand for hydrogen will continue to increase yearly. Alternative cheap electrochemical catalysts used in PEMWE for hydrogen production need to be developed. The high cost associated with components such as precious metal catalysts and the proton conducting membrane is the primary challenge facing the Proton Exchange Membrane (PEM) water electrolyzer [
7]. Significant efforts by various researchers aiming to reduce the cost of the PEM water electrolyzer electrocatalysts and improve their specific performance and durability using the precious metal loading requirement have been conducted [
7,
8,
9].
At the anode, the electrocatalyst plays a critical role as it undergoes the oxygen evolution reaction (OER), exhibiting the highest overpotential in standard operating conditions [
7,
9]. Similar to the oxygen reduction reaction (ORR) in Proton Exchange Membrane Fuel Cells (PEMFC), the OER is kinetically sluggish, since it is thermodynamically and kinetically unfavorable to remove four electrons for oxygen–oxygen bond formation [
9].
Among metal oxides, IrO
2 exhibits good durability with the second-best activity, while RuO
2 exhibits the highest activity with poor durability [
10]. Several methods have been studied for synthesizing nano-sized metal oxides, including Adams fusion, the molten salt method, metal–organic chemical vapor deposition method, sulphite complex route method, sol–gel method, modified polyol method, and hydrothermal method [
7]. However, in the context of the scaling-up process, some of these methods involve steps requiring complex equipment and present technical and economic challenges [
7].
In this study, research was carried out to synthesize nanostructured Ru-modified IrO2 electrocatalysts to improve the catalytic activity and the corrosion stability of the modified metal oxide compared to pure noble metal oxide electrocatalysts and to reduce the cost of the catalysts. Modifying IrO2 catalysts with ruthenium (Ru) presents a promising avenue to overcome the challenges associated with pure IrO2 and unlock improved performance in PEM electrolyzers. Ruthenium, characterized by lower cost and relatively more abundant supply than iridium, addresses the economic barriers associated with IrO2 catalysts. Furthermore, incorporating Ru can significantly enhance the electrochemical activity of the catalyst, reducing the overpotential required for the OER. This translates to improved energy efficiency and reduced electrolysis costs. Moreover, Ru modification can potentially mitigate the stability issues of IrO2 by providing enhanced structural stability and resistance to degradation under harsh operating conditions. The synergistic effects of the IrO2-Ru hybrid catalyst hold promise for achieving high catalytic performance, increased durability, and cost-effectiveness, thereby accelerating the adoption of PEM electrolyzers for sustainable hydrogen production.
5. Results and Discussion
Modified catalysts: Physical and electrochemical characterization of in-house Ir0.8Ru0.2O2 catalyst.
There have been extensive studies of Ir-Ru mixed oxides for many years. According to the literature, the addition of Ru to IrO
2 improves the electrocatalytic activity of IrO
2 [
32,
33]. In this study, IrO
2 was modified by adding Ru, the composition of Ru to Ir was determined by in-house (IH) literature and, according [
33] to the best performing Ru-modified IrO
2 catalyst, had a composition ratio of Ir to Ru of 0.8:0.2 respectively.
The EDS results of IrO
2 commercial, RuO
2 commercial, and Ir
0.8Ru
0.2O
2-IH are represented by 3. The data from EDS shows trace amounts of impurities in the IrO
2, which could be due to the synthesis procedure, or the trace amounts were detected from the tray the analyte was placed in. However, both the RuO
2 and Ir
0.8Ru
0.2O
2-IH samples were found to be pure the ratio of Ir to Ru was found to be 0.8:0.2, respectively.
Table 4 shows the elemental composition of commercial and IH samples.
Figure 3 shows the XRD spectra of the IH-Ir
0.8Ru
0.2O
2 catalyst synthesized at 350 °C as well as both commercial IrO
2 and RuO
2 catalysts. The IrO
2 and RuO
2 standard peaks were assigned using the data available from the JCPDS database. Both commercial catalysts IrO
2 and RuO
2 represent a similar presence of the crystalline phase, which is confirmed when their similar characteristic phases are cross-referenced with the JCPDS database, JCP2-43-1019 for IrO
2 and JCP2-40-1290 for RuO
2 [
34]. Comparing the peaks of the IH-Ru-modified IrO
2 to the commercial catalysts (IrO
2 and RuO
2), the commercial catalysts have narrower peaks compared to IH-Ru-modified IrO
2 catalyst. This indicates that the IH-Ru-modified IrO
2 is more amorphous in nature and the commercial catalysts being more crystalline in nature. According to literature, the amorphous phase usually has smaller particle size than the crystalline phase [
35]. For both commercial samples, the (110) facet is there the main diffraction peaks however, the (101) facet was the main diffraction peak for the IH sample, and a similar result was achieved by [
7] by using a synthesis temperature of 350 °C. The crystallite sizes at each facet were calculated using the Scherrer formula below.
The crystallite sizesw for the (110), (101) and (211) facets were calculated using Equation (1) and reported in
Table 5 along with the average crystallite sizes of both the commercial and IH samples.
Figure 4 shows the surface morphology of the IH Ru-modified IrO
2 and the commercial IrO
2 and RuO
2 catalyst at a scale of 100 nm. There is a drastic change in the surface morphology of the IH sample compared to the commercial samples. XRD and BET results correlate to the change in surface morphology, where the IH sample has a smoother surface compared to the commercial samples.
Figure 5 represents the TEM images of the IH Ru-modified IrO
2 and, commercial IrO
2 and RuO
2. The TEM image of the IH samples shows small particles that are extremely agglomerated compared to the commercial samples, thus making it difficult to particle size. The commercial samples in
Figure 5a,c show cubic particles. The particle size of the IH Ir
0.8Ru
0.2O
2 and commercial IrO
2 and RuO
2 are reported below.
Figure 6 represents the N
2 adsorption–desorption analysis for commercial IrO
2 and RuO
2 and Ir
0.8Ru
0.2O
2-IH. Both the Ir
0.8Ru
0.2O
2-IH and commercial RuO
2 show distinct hysteresis loops; however, the IrO
2 does not have the hysteresis loop. The BET surface area reported in
Table 6 shows that Ir
0.8Ru
0.2O
2-IH has the largest surface area compared to the commercial RuO
2 catalysts, with IrO
2 having the smallest surface area. The significant increase in surface area for the Ir
0.8Ru
0.2O
2-IH sample compared to the commercial IrO
2 and RuO
2 samples is attributed to the nature of synthesized Ir
0.8Ru
0.2O
2, which is amorphous. Amorphous materials usually have higher surface areas due to their irregular structure and the random arrangement of atoms, which creates more surface irregularities and pores.
There is a direct correlation between surface area and pore size, with the IH sample having the smallest pore size and commercial IrO2 having a larger pore size. The BET results correlate with the results found in TEM, SEM and XRD.
Figure 7 represents the CV analysis of Ir
0.8Ru
0.2O
2-IH and commercial IrO
2 and RuO
2. The addition of Ru to IrO
2 caused the CV of Ir
0.8Ru
0.2O
2-IH to resemble that of RuO
2 more than IrO
2 with a distinct negative tail at the cathodic potential scan at 0 V vs. RHE, which is attributed to hydrogen adsorption (H
ads) [
7,
32]. The Ir(III)/Ir(IV) and Ir(IV)/Ir(V) redox couples are reported in
Table 7. An extra peak can be seen for the commercial IrO
2 which was reported by [
33] and suggested it could be the presence of active Ir(III) sites.
Figure 8 represents the LSV analysis of Ir
0.8Ru
0.2O
2-IH and commercial IrO
2 and RuO
2. LSV results show an increase in catalytic activity for OER with the addition of Ru to IrO
2, which is expected since RuO
2 is known to have higher catalytic activity than IrO
2. However, as seen in
Figure 8, the catalytic activity of RuO
2 decreases with increased potential. This result is due to the harsh acidic environment which causes corrosion and catalyst degradation, making the RuO
2 catalyst less stable than IrO
2.
Table 8 represents the current densities of Ir
0.8Ru
0.2O
2-IH and commercial IrO
2 and RuO
2 at the operational potential of 1.7 V as this is the typical potential a PEM electrolyzer operates. From the results reported in
Table 8, it is seen that Ir
0.8Ru
0.2O
2-IH is 3 times more active than both commercial IrO
2 and RuO
2.
CP studies the OER stability of the catalyst at a fixed current,
Figure 9 shows the CP results of the Ir
0.8Ru
0.2O
2-IH and commercial IrO
2 and RuO
2 that were obtained at the current density of 10 mA.cm
−2.
Table 9 shows the summary of the OER stability of the same catalysts. The Ir
0.8Ru
0.2O
2-IH sample had excellent stability at a constant potential of ±1.5 V over 24 h. This result is significant compared to the commercial sample, with RuO
2 being the least stable, shown in both
Figure 9 and
Table 9.