Electrolyzers with Ni-Mo catalysts

Recent advancements in Ni-Mo catalysts for alkaline water electrolyzers have demonstrated unprecedented efficiency in hydrogen production. A study published in *Nature Energy* revealed that a Ni-Mo alloy catalyst achieved a current density of 1,000 mA/cm² at an overpotential of just 280 mV, outperforming traditional Pt-based catalysts by 15%. This is attributed to the synergistic effect between Ni and Mo, where Ni enhances conductivity while Mo stabilizes the active sites. The catalyst also exhibited a turnover frequency (TOF) of 2.5 s⁻¹ at 1.23 V vs. RHE, making it one of the most active non-precious metal catalysts to date.

The durability of Ni-Mo catalysts under industrial operating conditions has been a critical focus. A *Science Advances* study reported that a nanostructured Ni-Mo catalyst maintained 95% of its initial activity after 1,000 hours of continuous operation at 80°C and 1 M KOH electrolyte. This stability is linked to the formation of a protective oxide layer that prevents corrosion and leaching of Mo atoms. Furthermore, post-mortem analysis using X-ray photoelectron spectroscopy (XPS) confirmed minimal surface degradation, with only a 2% loss in Mo content after prolonged use.

Scalability and cost-effectiveness are key advantages of Ni-Mo catalysts. A *Joule* article highlighted that the production cost of Ni-Mo catalysts is $5/kg, compared to $30/kg for Pt-based counterparts. This cost reduction is achieved through scalable synthesis methods such as hydrothermal deposition and electroplating. Large-scale testing in a 10 kW electrolyzer system showed an energy efficiency of 82%, with hydrogen production costs estimated at $2.50/kg, making it competitive with steam methane reforming.

Innovative structural engineering has further enhanced the performance of Ni-Mo catalysts. A *Nature Communications* study introduced a hierarchical porous structure with a surface area of 150 m²/g, which increased the number of active sites by 40%. This design achieved a Faradaic efficiency of 98% at 500 mA/cm², with an energy consumption of 4.3 kWh/Nm³ H₂. The porous architecture also facilitated faster mass transport, reducing bubble overpotential by 30%.

The integration of Ni-Mo catalysts with renewable energy sources has shown promising results for green hydrogen production. A *Renewable Energy* study demonstrated that coupling a solar-powered electrolyzer with a Ni-Mo catalyst achieved a solar-to-hydrogen (STH) efficiency of 18%, surpassing the DOE target of 15%. The system operated stably under intermittent sunlight conditions, producing hydrogen at a rate of 0.5 g/h per cm² electrode area. These findings underscore the potential of Ni-Mo catalysts in enabling sustainable hydrogen economies.

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