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The hydrogen evolution reaction (HER) represents a pivotal process for generating clean hydrogen fuel, which could play a vital role in addressing the climate crisis. However, a major challenge remains in transitioning this reaction from laboratory settings to large-scale commercial production while keeping expenses manageable.
Recent research conducted by Tohoku University has shed light on enhancing HER performance, as detailed in a study published in Advanced Energy Materials on April 3, 2025. The researchers have introduced a surface reconstruction pathway that enables the development of robust, non-noble metal-based cathodes. These cathodes have shown the capability to sustain their effectiveness for over 300 hours, aligning closely with the U.S. Department of Energy’s target for hydrogen production costs by 2026, estimated at $2.00 per kg of hydrogen. This breakthrough may significantly advance the design of efficient non-noble metal cathodes for commercial proton exchange membrane (PEM) applications, thereby facilitating the transition from research to industrial production.
This study focused on transition metal phosphides (TMPs) as potential catalysts to enhance HER efficiency, given the traditional reliance on noble metals, which are often costly and less sustainable. Recognizing a gap in knowledge regarding non-noble metals, the research team embarked on an exploration of TMPs, revealing their promise as both durable and cost-effective alternatives.
The investigation centered on fluorine-modified cobalt phosphide (CoP), employing operando X-ray absorption spectroscopy (XAS) and Raman analysis to assess its surface reconstruction and active sites. The introduction of fluorine into the CoP lattice creates phosphorus vacancy sites on the surface, which increases the presence of active sites crucial for accelerating HER.
Heng Liu from the Advanced Institute for Materials Research (WPI-AIMR) remarked, “This reconstructed cobalt shows exceptional activity, operating effectively in acidic conditions while maintaining approximately 76 W for over 300 hours. We are approaching an economically viable method for hydrogen production, with the estimated cost through this approach being $2.17 per kg of hydrogen—just slightly above the targeted production costs for 2026.”
The findings indicate that the surface reconstruction of the fluorine-modified cobalt phosphide cathode led to significant improvements in its catalytic activity. Importantly, the experiments extended beyond traditional lab settings with three-electrode setups, paving the way for application in commercial-scale PEM electrolyzers. These advancements in HER catalyst development could provide essential insights for designing other non-noble metal-based cathodes.
“Our ultimate aim is to translate research advancements into real-world applications,” Liu added. “This progress brings us closer to crafting viable options for commercial PEM use.”
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