Ammonia (NH3) is a critically important molecule, necessary to produce fertilizers and is also used in a variety of household chemical and as a precursor in pharmaceuticals. Additionally, NH3 has a relatively large energy density and can be liquified at mild conditions, making it appealing as not only a chemical feedstock but also as an energy storage vector. Unfortunately, the now century old Haber Bosch (HB) process remains the only way to produce NH3 on a large scale. The HB process is one of the most energy intensive and carbon dioxide emitting processes and is therefore essential to decarbonize as we transition into a greener future. The electrochemical transformation of reactive nitrogen-species is a promising, carbon neutral pathway for NH3 synthesis. Typical approaches utilize di-nitrogen (N2) as a reactant; however, the success of these systems remains unproven. Utilizing a more oxidized form of nitrogen, nitrate (NO3-), presents several advantages such as increased solubility in aqueous electrolytes and favorable adsorption energies, helping to increase the NO3- to NH3 selectivity. The electrochemical nitrate reduction reaction (NO3RR) is a complex 8e- transfer reaction, where the reaction pathway and participation of reaction intermediates is largely unknown. This dissertation addresses these issues by fundamental studies partitioning the reaction pathway over distinct catalytic sites in a bi-metallic system. Then moving to develop a series of physically relevant NO3/NO2RR activity descriptors. Finally, the knowledge gained from the fundamental studies is applied to create an active particle-active support catalyst system, achieving the NO3RR to NH3 at industrial current densities. Specifically, the studies are outlined below.
i) Highly durable and selective Fe-and Mo-based atomically dispersed electrocatalysts for nitrate reduction to ammonia via distinct and synergized NO2–pathways
An atomically dispersed bi-metallic FeMo-N-C catalyst was developed and was shown computationally and experimentally that the Fe-Nx sites favor NO2- to NH3 conversion, while the Mo-Nx sites favor NO3- to NO2- conversion. These sites were synergized to achieve a NO3- to NH3 efficiency of 94%. Additionally, DFT uniquely demonstrated that over highly oxyphilic sites, such as Mo-Nx the real active site during the reaction is *O-Mo-Nx and can simultaneously adsorb multiple intermediates.
ii) Elucidating electrochemical nitrate and nitrite reduction over atomically dispersed transition metal sitesA library of 3d, 4d, 5d and f-metal atomically dispersed Metal-Nitrogen-Carbon catalysts were synthesized and extensively characterized for their atomically dispersed nature and M-Nx coordination. Electrochemical NO3RR and NO2RR were performed to obtain experimental activity descriptors. DFT was used to generate a series of computational activity descriptors. The experimental and computational activity descriptors were correlated to develop a set of physically relevant computational descriptors, such that the NO3/NO2RR activity of M-N-C catalysts could be accurately predicted with a simple descriptor. Additionally, isotopic doping experiments revealed the complex NO2- production consumption mechanism over the M-N-C catalysts, confirming the 2e- + 6e- transfer pathway rather than the commonly assumed direct 8e- pathway.
iii) Synergizing γ-Fe2O3 nanoparticles on single atom Fe-N-C for nitrate reduction to ammonia at industrial current densities An active particle-active support catalyst system was synthesized by reducing γ-Fe2O3 nanoparticles onto an atomically dispersed Fe-N-C support. The catalyst system was characterized electrochemically to demonstrate the increase in NO3RR performance of the γ-Fe2O3/Fe-N-C system over a γ-Fe2O3/XC72 system. Uniquely, the γ-Fe2O3/Fe-N-C system showed potential independent behavior on the FENH3, allowing for a reductive potential up to -1.2 V vs. RHE, while maintaining a 100% FENH3 and a high YieldNH3 over 9 mmol hr-1 cm-2. An economic analysis invesitagting the levelized cost of NH3 revealed it is more beneficial to reduce the levelized cost of NH3 to operate at a higher over potential of -1.0V at a lower energy efficiency, with a very high NH3 partial current density (1.3 A/cm2). Post-mortem XPS revealed that during the pre-reduction activation step, a surface layer of Fe2+/Fe0 is formed, resulting in the ultra-high NO3RR activity observed.