High Performance Cathodes for Water Electrolysers

Abstract

A cathode for hydrogen evolution in an electrolytic cell, comprising a metallic substrate, and a coating consisting of substantially pure ruthenium oxide, is disclosed. The inventive cathode provides enhanced performance and service life under unsteady and intermittent powering, such as powering from solar cells; a process for coating the metallic substrate is also disclosed.

1 . A water electrolysis method to generate hydrogen (H 2 ) and oxygen (O 2 ) from water, said method comprising the step of providing electrolysis of an alkaline aqueous solution in at least one electrolytic cell comprising at least an anode and a cathode, wherein water is decomposed into hydrogen and oxygen and the so produced hydrogen is collected at said at least one cathode of said at least one cell, the cathode comprising:
 a metallic substrate made of a material selected between mild steel, steel alloys, nickel and nickel alloys, and   a coating layer provided on said metallic substrate and consisting of ruthenium oxide without alloyed or added elements,   wherein said cathode is obtainable according to a process comprising at least the steps of:   a) pre-treating said metallic substrate;   b) preparing an activating solution by dissolving an appropriate precursor of ruthenium oxide in a solvent;   c) applying said activating solution on the metallic substrate; and   d) providing a final thermal treatment to fix the coating on the metallic substrate;   wherein step b) is carried out by dissolving ruthenium chloride in an alcoholic solution; and   wherein said ruthenium chloride is hydrated trichloride RuCl 3 .nH 2 O, and said solution is based on iso-propanol or 2-propanol, added by distilled water and by aqueous hydrochloric acid.   
     
     
         2 . The method according to  claim 1 , wherein said coating is in the range from 0.1 to 2 mg/cm 2 . 
     
     
         3 . The method according to  claim 1 , wherein said cathode has a form selected from the group consisting of plate, perforated or expanded sheet, and greed. 
     
     
         4 . The method according to  claim 1 , wherein said electrolytic cell is powered by a renewable energy source. 
     
     
         5 . The method according to  claim 1 , wherein said step c) is carried out by a sequence of applications of activating solution to the metallic substrate, each application being followed by intermediate steps of dripping excess of solution from the metallic substrate, and drying the cathode before the next application. 
     
     
         6 . The method according to  claim 5 , wherein drying is performed in a hot-air oven, with air at a temperature between 150 and 350° C., and a residence time of the substrate of 3 to 12 min. 
     
     
         7 . The method according to  claim 5 , wherein the application of activating solution is repeated 5 to 15 times. 
     
     
         8 . The method according to  claim 1 , wherein said step d) of a final thermal treatment is carried out in a hot-air oven, at a temperature between 250 and 400° C. and with a treatment time of 1 to 2 hours. 
     
     
         9 . A process for making a cathode for use in a method according to  claim 1 , said process comprising at least the steps of:
 a) pre-treating said metallic substrate;   b) preparing an activating solution by dissolving hydrated trichloride RuCl 3 .nH 2 O in an alcoholic solution based on iso-propanol or 2-propanol, added by distilled water and by aqueous hydrochloric acid;   c) applying said activating solution on the metallic substrate;   d) providing a final thermal treatment to fix the coating on the metallic substrate.   
     
     
         10 . The process according to  claim 9 , wherein said step c) is carried out by a sequence of applications of activating solution to the metallic substrate, each application being followed by intermediate steps of dripping excess of solution from the metallic substrate, and drying the cathode before the next application. 
     
     
         11 . The process according to  claim 10 , wherein drying is performed in a hot-air oven, with air at a temperature between 150 and 350° C., and a residence time of the substrate of 3 to 12 min. 
     
     
         12 . The process according to  claim 10 , wherein the application of activating solution is repeated 5 to 15 times, 
     
     
         13 . The process according to claim  16 , wherein said step d) of a final thermal treatment is carried out in a hot-air oven, at a temperature between 250 and 400° C. and with a treatment time of 1 to 2 hours. 
     
     
         14 . The method according to  claim 2 , wherein said coating is in the range from 0.4 to 1 mg/cm2.