Making green hydrogen from seawater instead of fresh water requires electrocatalysts that can survive the salt, corrosion, and impurities that destroy current materials. This project aims to develop bifunctional perovskite catalysts—specifically, layered Ruddlesden–Popper oxides—that can split seawater into hydrogen and oxygen efficiently and stably. The UK will need 7.5 to 13.8 million tonnes of hydrogen by 2050, and conventional electrolysis consumes about 9 kilograms of fresh water per kilogram of hydrogen, a major barrier to scaling up. Seawater is abundant, but its harsh chemistry degrades electrodes quickly. The team targets a current density of 10 mA cm⁻² at less than 1.5 volts, with stability exceeding 200 hours in an electrolyser cell. They will use a continuous hydrothermal flow synthesis method to produce the catalysts rapidly and in high throughput, then tune their performance through heteroatom substitutions and corrosion-resistant surface layers. Advanced in-situ characterisation will reveal how the catalyst and electrolyte interact in real time. If successful, the work could make direct seawater electrolysis commercially viable, reducing pressure on freshwater supplies for hydrogen production. The material design strategies will also apply to CO₂ reduction, fuel cells, batteries, and sensors.
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The transition to renewable energy is crucial for the UK to meet its climate goals and reduce greenhouse gas emissions. Hydrogen, as a clean and versatile energy carrier, is key to this effort. By 2050, the UK will need 7.5 to 13.8 million tonnes (Mt) of hydrogen, potentially covering up to a third of final energy consumption. Globally, hydrogen demand is expected to reach 115 Mt by 2030. Electrolysis, a process that splits water into hydrogen and oxygen using electricity, is considered a promising method for producing green hydrogen. However, it faces significant hurdles, particularly the high consumption of fresh water—about 9.0 kg of water per 1.0 kg of hydrogen. This poses a barrier to industrializing green hydrogen. Seawater, an abundant resource, offers an alternative but brings challenges like corrosion and impurities that affect the efficiency and lifespan of electrocatalysts. Advancements in electrode materials are needed to make seawater electrolysis more efficient and viable. This ambitious project aims to address these challenges by developing robust, cost-effective and efficient bifunctional perovskite catalysts capable of withstanding the harsh conditions of seawater electrolysis and producing economically viable green hydrogen. The project intends to achieve a current density of 10mA cm-2 with less than 1.5 V and stability exceeding 200 hours using these perovskite electrocatalysts in an electrolyser cell. The project’s success relies on combining expertise in high-throughput clean material engineering (LSBU), in-depth characterization, and the utilization of specialized equipment to accelerate understanding and optimization (LSBU/Oxford), along with electrode development (UoE/LSBU) for advancing catalytic materials for efficient energy conversion. The catalysts, based on the layered Ruddlesden–Popper (R–P) structure of Aurivillius perovskite oxides (ABO3), will be produced via an environmentally friendly, rapid, and controllable continuous hydrothermal flow synthesis method, addressing current synthesis challenges. To accelerate discovery, we will employ a high-throughput mode, enabling rapid synthesis, screening and optimization of catalyst properties. Selectivity and stability will be achieved through heteroatom substitutions at the A and B sites, nanoarchitecture tuning, and corrosion protection via surface modification and the application of a corrosion-resistant layer. Advanced in-situ characterization techniques will be used to observe the real-time interactions between the catalyst and electrolyte, as well as the dynamic formation of the corrosion-resistant layer. This will directly and clearly reveal the underlying reaction mechanisms of the process. We believe that the fabrication and characterization of advanced catalytic materials, along with the study of energy conversion mechanisms and the investigation of electrode/electrolyte/catalyst interfaces, charge carrier dynamics, and catalytic reactions, will provide a profound understanding and firm basis for constructing a commercially feasible electrolyser cell for direct seawater electrolysis. This transformative project aims to enhance the development of electrocatalysts, which are essential for improving the efficiency and economic viability of seawater electrolysis. The multidisciplinary nature of the proposed project is not limited to seawater splitting. The material design, fabrication, and characterisation strategies developed in this project will contribute to other advanced materials research frontiers, such as CO2 reduction, fuel cells, batteries, sensors, photocatalysis, and electro-ceramics. Additionally, this project will create new opportunities for collaboration with leading researchers and experts from prestigious national Hubs and Centres.
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