Key Takeaways & Executive Findings
- •• • Pt@N/CFP achieves a cell voltage of 1.688 V at 1000 mA cm−2 in an AEM electrolyzer with alkaline seawater at 80 °C, outperforming conventional Pt/C across the entire current density range, indicating superior activity for industrial-scale hydrogen production. • • The catalyst maintains stable operation for over 300 h at 1000 mA cm−2 in 1.0 M KOH + seawater at 80 °C without noticeable degradation, demonstrating exceptional durability under harsh conditions. • • At 80 °C, the AEM electrolyzer with Pt@N/CFP delivers cell voltages of 1.688 V and 1.831 V at current densities of 1 and 2 A cm−2, respectively, showing enhanced performance with increasing temperature. • • The strong metal-support interaction (SMSI) between Pt and N-doped carbon aerogel reduces water dissociation energy, optimizes hydrogen adsorption free energy (ΔG H*), and lowers Cl− adsorption, addressing both activity and chloride poisoning challenges.
Abstract
Industrial-scale hydrogen production from seawater is a paramount goal for a sustainable energy future, yet it is severely hampered by the rapid deactivation of electrocatalysts under harsh operating conditions. Here, we introduce a robust self-supporting aerogel catalyst designed to address the two intertwined challenges of activity and stability in high-current-density seawater electrolysis. Our strategy involves creating strong metal-support interactions by anchoring ultrasmall platinum nanoparticles onto a porous N-doped carbon aerogel (Pt@N/CFP). Theoretical calculations reveal that this unique Pt-N interface serves a dual critical function: it not only lowers the kinetic barrier for water dissociation but also creates an electronic shield that effectively prevents chloride ion poisoning of the Pt active sites. When implemented as the cathode in a practical anion-exchange membrane (AEM) electrolyzer, the Pt@N/CFP catalyst demonstrates exceptional performance, achieving a low cell voltage of 1.688 V at an industrial-grade current density of 1000 mA cm−2 and maintaining outstanding stability for over 300 h. This work provides guidance for creating exceptionally durable catalysts capable of withstanding extreme electrochemical environments.
1. Introduction
Industrial-scale hydrogen production from seawater is a critical step toward a sustainable energy economy, yet it is hindered by the rapid deactivation of electrocatalysts under harsh operating conditions. Conventional platinum-based catalysts, while highly active for the hydrogen evolution reaction (HER), suffer from prohibitive cost and susceptibility to chloride ion poisoning in seawater electrolytes. At industrial current densities exceeding 200 mA cm−2, the challenges intensify: accelerated reactant consumption, bubble-induced mass transport limitations, and corrosive chloride ions compromise both activity and stability. Existing catalysts often fail to maintain performance under these demanding conditions, limiting the feasibility of large-scale seawater electrolysis.
This work introduces a self-supporting aerogel catalyst, Pt@N/CFP, which addresses these bottlenecks through a dual strategy: anchoring ultrasmall platinum nanoparticles onto a porous N-doped carbon aerogel creates strong metal-support interactions that lower the water dissociation barrier and form an electronic shield against chloride adsorption. The 3D interconnected porous channels facilitate mass transport and expose abundant active sites, while the robust SMSI ensures catalyst adhesion under high-current-density operation. In a practical anion-exchange membrane electrolyzer, Pt@N/CFP achieves a low cell voltage of 1.688 V at 1000 mA cm−2 and maintains stability for over 300 hours, demonstrating its potential for industrial-scale seawater splitting.
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Meihong Liao, Quezhong Yan, Qinggong Zhu, Siqi Wang, Shuaishuai Zhou, Jingjie Dai, Yichao Huang, Zhenjiang Li (2026). Poison-proofing platinum nanocatalysts with nitrogen for industrial-scale seawater splitting. SCIENCE CHINA Materials. https://doi.org/10.1007/s40843-025-4065-6
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Frequently Asked Questions
What is the specific role of nitrogen doping in enhancing the catalytic activity and stability of Pt@N/CFP?
Nitrogen doping creates a Pt-N interface that lowers the kinetic barrier for water dissociation and optimizes the hydrogen adsorption free energy (ΔG H*). Additionally, it forms an electronic shield that reduces chloride ion adsorption, preventing poisoning of Pt active sites. This dual function is confirmed by theoretical calculations and experimental results, leading to enhanced HER activity and stability in seawater.
How does the Pt@N/CFP catalyst perform under industrial-scale current densities compared to conventional Pt/C?
In an AEM electrolyzer with alkaline seawater at 80 °C, Pt@N/CFP achieves cell voltages of 1.688 V and 1.831 V at current densities of 1 and 2 A cm−2, respectively. Over the entire current density range, Pt@N/CFP exhibits lower cell voltages than Pt/C, indicating superior activity. Moreover, it maintains stable operation for over 300 hours at 1000 mA cm−2 without noticeable degradation.
What are the main degradation mechanisms for Pt-based catalysts in seawater electrolysis, and how does Pt@N/CFP mitigate them?
The primary degradation mechanisms include chloride ion poisoning, which blocks active sites and induces corrosion, and mechanical stress from bubble evolution at high current densities. Pt@N/CFP mitigates these through the Pt-N interface that repels Cl− ions, and the strong metal-support interaction that firmly anchors the catalyst to the substrate, preventing detachment under vigorous bubble evolution.
What is the significance of the 3D porous structure of the carbon aerogel support?
The 3D interconnected porous channels expose more active catalytic sites and facilitate faster mass transfer of reactants and products, reducing bubble-induced barriers. This is crucial for maintaining high performance at industrial current densities where mass transport limitations are pronounced.
How does temperature affect the performance of the AEM electrolyzer with Pt@N/CFP?
Increasing the operating temperature from 40 to 80 °C reduces the cell voltage at identical current densities. At 80 °C, the electrolyzer achieves 1.688 V at 1 A cm−2 and 1.831 V at 2 A cm−2, demonstrating improved kinetics and reduced ohmic losses at higher temperatures.
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